Aux Switch 5 Issue

[D00Mlemon]

[RESOLVED]
*Bad pod light relay popped 10A fuse in the main fuse box. I guess the Aux switch fuses are labeled as "up fitter switch #" so I didn't see them at first.


Background: I recently installed fog and pod lights on my rig. They worked perfectly for about 2 months then one pair suddenly stopped working so I took out the multimeter and probed out the issue. I found that the pod light relay was busted and the aux line connected to that relay was not supplying power unlike the other switches. I tested the aux switch directly from the wire bundle to the negative terminal of the battery and nothing.

So I found one bad relay, which is easy to replace, but I'm not sure how to deal with the aux switch. I find it strange that the switch itself is lighting up but isn't supplying power. I checked the main fuse box and couldn't find anything. Does anyone know if there is a hidden fuse for the aux switches? Maybe the aux switch itself is bad? Also if anyone has had any similar problems I would appreciate it. I don't want to replace the whole aux switch assembly but I have a feeling that's the way this is going.

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[Raptor911]

I know you said you tested the switch 5 at the wire bundle but do you have test light? Something like this >> https://www.amazon.com/WINAMOO-Prem...34092&sprefix=automotive+test+,aps,795&sr=8-5

BTW .. if your switch 5 is bad, it should be covered under warranty.

 

[ChrisB351]

Thats a warranty issue

 

[RagnarKon]

The Aux switch itself is controlling a relay in the battery junction box. That relay inside the BJB controls power to the associated Aux line near the fuse box.

Not sure exactly which line you were probing... but if the Aux switch itself is working and you are getting nothing on the associated Aux line. That means either the fuse for the Aux line is bad, or that relay inside the BJB is bad. If it's the latter... you need an all-new BJB because those relays aren't serviceable.

 

[toymaster]

Below is a diagram of the power circuit, not the switches in the cab.

Is the "pod relay" you are referring to a relay you added to run the lights? If so, sounds like the added relay, when it shorted, took out the ford factory relay (that is operated by the in-cab switch).

In other words I think you may have to replace the ford factory relay and the "pod relay".

https://www.bronco6g.com/forum/thre...g-diagram-video-discussions.13485/post-593783

 

[D00Mlemon]

Below is a diagram of the power circuit, not the switches in the cab.

Is the "pod relay" you are referring to a relay you added to run the lights? If so, sounds like the added relay, when it shorted, took out the ford factory relay (that is operated by the in-cab switch).

In other words I think you may have to replace the ford factory relay and the "pod relay".

https://www.bronco6g.com/forum/thre...g-diagram-video-discussions.13485/post-593783

Thanks for the diagram

So to clarify, I installed the relay as part of the pod light kit to pull higher amps from the battery. This part is external to the vehicle electronics.

So some more info: I am using 3 of the aux lines 4,5,6 for pod and fog lights, which I believe corresponds to D,E,F. I have power on some of the switches so I assume the battery junction box is working. I do not read a voltage when connecting wire E to the negative battery terminal, but I do on the other switches. Also the AUX switch lights up amber when flipping them in the cab so there is power running up there...

Is wire E possible bad?

 

[D00Mlemon]

I know you said you tested the switch 5 at the wire bundle but do you have test light? Something like this >> https://www.amazon.com/WINAMOO-Premium-Automotive-Extended-Circuits/dp/B08D9RY532/ref=sr_1_5?keywords=automotive+test+light&qid=1685734092&sprefix=automotive+test+,aps,795&sr=8-5

BTW .. if your switch 5 is bad, it should be covered under warranty.

I have a multimeter for testing which has some nice features, I would recommend.

 

[D00Mlemon]

Found the issue...

Bad pod light relay popped 10A fuse in the main fuse box. I guess the Aux switch fuses are labeled as "up fitter switch #" so I didn't see them at first.

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