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How to Fix Headlite Wipers Posted by TonyJ [Email]  (#407)  [Profile/Gallery]
(more from TonyJ) on Mon, 29 Aug 2005 19:18:07
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I usually post on the 9000 list, but in a junk yard the other day, I noticed that 900s and 9-3s have the same headlight wipers, so I though this might be useful to you.
If your motors are completely dead, Check the fuses first.
When the polyfuses start to go, it is most noticeable in warmer weather when they more-easily reach their "open" state. The usual symptom is that the blades annoyingly stop at odd angles. This could also be caused by dirty contacts, but my most common experience has been that the problem will return soon until you replace the polyfuse. It's not expensive and little extra effort once you have the motor out and apart. You could also stick a piece of metal in place of a polyfuse, but that would risk frying the motor if the blades ever encountered extra drag, e.g. are frozen in ice.
If the motor is bad or there is a mechanical problem, you can find replacements in junkyards or buy new ones from one of our site sponsors.
See my previous 9000 posts on this subject for technical details. The following procedure has worked in two cases thus far, with no subsequent failures. The photos are viewable via the Member Gallery, thanks to member "diskullman" of the 900 BB. I'm not sure what the 3rd picture is or where it came from. The procedure:
1. Order some PolySwitch resettable fuses from, for example, Digikey (http://www.digikey.com). The RGE300-ND holds at 3 Amps, trips at 5Amps, and seems to be a good replacement; it costs only $0.61. You may want to order 10 (price break) in case you smash one or two preparing it for installation and to be ready for other wiper failures.
Figure 1.jpg shows (top row, left to right):
a. The original polyswitch,
b. The RGE300 as delivered (leaded and packaged with an insulating ceramic coating)
c. The RGE300 with flattened leads, and
d. The RGE300 ready to plug into your wiper motor unit.
2. Using pliers with smooth (not serrated) jaws or a small hammer and anvil, flatted each lead as in Figure 1.
3. Bend each lead back over the middle of the body, one on each face as in Figure 1.
4. Where the leads extend past the body, bend them around the edge and cut them off so there is about 1/64" between them as in Figure 1.
5. Remove the wiper unit from the car (Grille, headlight unit, and corner light unit all need to come out first..this part may differ for 900s or 9-3s). Getting the connector apart is usually an adventure and may need your favorite persuasion fluid and words of encouragement.
6. Using a flat blade screwdriver, release the tabs that hold the cover on, then pop it off. You may want to clean it up and add some fresh grease to the gears.
7. Using needle nose pliers, pull out the original square device between the two copper strips next to the motor.
8. Then slip the prepared RGE-300 in place of it, lead end first, making sure it is securely wedged. See Figure 2.jpg. Fingers in the cover will hold it in place.
9. Test by applying 12 volts to the outer connector pins, + to red, and momentarily connecting the yellow and red wires to start it.
10. Re-assemble and re-install.
It works very well so far. If anyone comes up with a better device choice or technique, please post on the 9000 list. Good luck.
TonyJ
94 9000 Aero 5 sp. 96K
97 9000 CSE turbo 5 sp. 104K
posted by 24.34.16...
, Mon, 29 Aug 2005 19:18:07 <-- Viewing This Message, Tue, 30 Aug 2005 21:21:40
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