Headlight Wire Harness Problem - 2003 Adventurer

[DavidH477]

Just purchased this 2003 adventurer and it's fun discovering these issues. My headlight was out, so I replaced the bulbs and upon further investigation I found the issue.

It looks like this wire harness has already been replaced though, I'm concerned I'll be repeating the same issue if I just replace the harness. Does anyone know the proper voltages to check or anything like that?

I'm looking for a part number perhaps for this wire harness. Ill replace the headlight assembly also, for good measure. Thanks.

 

[DavidH477]

This is going to sound a little weird, but someone in the feedback section of the amazon listing for the headlights mentioned that they were the same headlights from an impala of the same year. I searched for IMPALA headlight harness and found one that looks very very similar, I suspect it's the same one. I ordered it just in case. https://www.amazon.com/dp/B0DCZ24YN5?psc=1&smid=A1STG4TH1C5KBC&ref_=chk_typ_imgToDp

Heres to hoping swapping the harness and headlight will fix the issue. If anyone has any comments please let me know!!

 

[Morich]

Got some info that might help?
First is the drawings which show the light wiring. But you need to know which, Ford or GM and it looks like the first three sheets and that connector seems to match the drawings on the right side?
Take a look and see what matches what you have, perhaps?
https://www.winnebago.com/Files/Files/Winnebago/Resources/Diagram/2003/03_g-ser_wire_141450.pdf
Then to ID the wires, Winnebago stamps ID on their small wires. Chassis wires from the chassis folks may not get that but worth a check? I would not expect it on the wires in the connector but back past the joints?

Then if you find ID on wires or on the drawings, you can "decode" that ID with this list. That can lead to finding if it is battery or ground?
https://www.winnebago.com/Files/Files/Winnebago/Resources/Diagram/electrical_guide.pdf

Depending which headlight it looks like DDL and DDM both go direct to a ground bar so I would expect the remaining wires to be battery at different phases of lighting?

Sometimes a bit of contact cleaner and wiggling is a good move?
Best of luck on the chase!

 

[tderonne]

Looks like where Winnebago connected the actual headlight wiring to the Ford supplied wires.

Drawings do confirm that: 2003 Adventurer Headlight Wiring Diagram

Ford/Adventurer wiring image attached. Colors match your pictures.

You have the headlights working, now you'll notice how bad they are. After you aim them correctly, you should look at adding relays to get more voltage to the bulbs, it'll help a bunch.

Wait a minute, rereading your post. And now I also see the burnt connector. The pigtail you found on Amazon should work. hopefully that fixes things for you.

(And yes, Winnebago used cheap knock off '02-'05 Impala lights on the Adventurers in '03-'05 (I think, without looking if it was '06 things changed) Good, OEM, light would be nearly impossible to find these days, but plenty of other knockoffs to at least have clear plastic, if that's an issue.)

(On a whim, I actually checked some GM info, you can still buy the headlights new from GM. '02-'04 version anyway, '05 version is discontinued. The glare caps changed in the lights, just have to match the bulb type to whether there's a cap in it or not. Price is around $200 each, actually not that terrible for proper OEM lights.)

 

[DavidH477]

Thank you both for the replies and huge amount of information. I replaced the headlights today, and the harness! You guys are amazing.