First and foremost, I ahve used the search button and returned nothing therefore yet another headlight post. Car is an 86! Problem, only the passenger side headlight would come up, determination faulty switch, I could manipulate both up with the switch apart and making the contacts myself. I replaced the switch. Now only the drivers side would come up. Hit the motor on the top and the thinbg would spin a little. I took the motor off and found a missing brush, so I made one and slodered it on and cleaned the shaft with some emory cloth. Now the motor would spin like crazy, much better than b4. upon reinstalling it, the thing refused to work again, so I took a look at the relay, it was bad, and had water in it. I tried the relay on the drivers side only to have the fuseable link catch on fire and I sliced my finger open when i ripped it apart (note to self wear gloves). so I put on the drivers side relay in its place and put a new relay on the passenger side. Now the passenger side will only go down. Why wont it go up??????? Also the relay will remain on and the headlight keeps checking to make sure it is down all the way, even though the limit switch is making contact. with the switch off and the headlights off, the thing remains energized and will click every 10 seconds or so. Any and all suggestions are very appreciated.

sorry, i got confused as to which side you took apart and which side is working currently.

Well thats cause the first time it was one side, now its the other lol. It is now the passenger side that will only go down not up. This is with a new passenger side relay, new switch, and rebuilt brushes on the motor.

I think the fusible links supply the power to make the headlights go up. I had an '84 that had a fuseholder with a 30A in it, replacing the links. Until I put a new fuse in it, I was pulling my hair out trying to get the headlights up. I hadn't tried it sooner because I thought it was something unrelated, the car had a bunch of extra wiring for stereo, radar detector, etc.

What size fuse is appropriate to replace the 0.5 sq mm links? Is 1 OK? Would individual fuses be better?

Thanks!
Cool forum!

http://www.fieros.de/en/articles/headlight.html

Spark1 + for you i needed that link. The fuseable link caught on fire when i wos working on it, and I thought i fixed it by using some bigger gauge wire. I will have to take a look at that.