Ford Falcon XK 1960-1962 Lighting, Horn and Instrument Trouble Shooting Guide

The lighting system, horn and instrument circuits of the Ford Falcon XK are part of the vehicle’s electrical system and are powered through the battery and charging system.

Faults within these systems are usually caused by loose wiring, burned out bulbs, faulty switches or defective relays. Because these circuits share power and grounding connections with other electrical components, careful diagnosis is necessary before replacing parts.

The following guides outline the most common symptoms and their likely causes.

Headlight and Lighting Trouble Diagnosis

All Headlights Do Not Light

If the headlights fail to operate, check the following:

1. Loose battery cable connection

2. Loose or broken wire from the battery to the headlight switch

3. Defective headlight switch

4. Disconnected or broken wire from the headlight switch to the beam selector switch

5. Defective beam selector switch

6. All headlight bulbs burned out

Simultaneous headlight failure may also occur if the generator voltage regulator is defective or improperly adjusted, causing bulb failure.

Individual Lights Do Not Light

If only one light fails to operate, check:

1. Burned out bulb

2. Loose or broken wiring connection to the bulb

Lights Burn Out Repeatedly

Frequent bulb failure may be caused by:

1. Loose or corroded electrical connections

2. Excessive vibration

3. Improperly adjusted or defective generator voltage regulator

Maintaining correct charging system voltage is essential to prevent repeated lighting failures.

Turn Indicator Trouble Diagnosis

Turn Indicator Lights Inoperative

If the indicator lights fail to operate, inspect the following:

1. Burned out fuse

2. Loose or broken wire from ignition switch to flasher

3. Defective flasher unit

4. Loose or broken wire from flasher to indicator switch

5. Defective indicator switch

6. Broken or loose wires from the switch to the indicator lamps

7. Burned out bulbs

Turn Indicator Lights Operate Incorrectly

If the indicators function improperly, check:

1. Burned out bulb

2. Loose or broken wiring from the switch to the indicator lamp

3. Defective indicator switch

4. Defective flasher unit

Turn Indicator Cancels Improperly

If the turn signal does not cancel correctly after turning, inspect:

1. Cancel cam incorrectly positioned on the steering wheel hub

2. Weak or loose coil spring on the switch plate assembly

Proper alignment of the cancel cam is necessary to ensure correct signal cancellation.

Horn Trouble Diagnosis

Horns Do Not Sound

If the horn fails to operate, inspect:

1. Loose connection at the horn button contact

2. Broken or open wire between the horn button and relay

3. Open wire to the horn relay

4. Inoperative relay

5. Horn units defective or improperly adjusted

One Horn Fails to Operate

If one horn works and the other does not, check:

1. Broken or loose wire from the relay to the horn

2. Defective or improperly adjusted horn

Horns Operate Continuously

If the horn sounds continuously, inspect:

1. Shorted wire to the horn button

2. Shorted horn relay

Instrument Trouble Diagnosis

Oil Pressure Indicator Light Inoperative

If the oil pressure warning light does not function, inspect:

1. Burned out indicator bulb

2. Loose or broken wire between the indicator light and switch

3. Defective oil pressure indicator switch

Charge Indicator Light Inoperative

If the charging system warning light fails to operate, check:

1. Burned out bulb

2. Loose or broken wires to the voltage regulator or generator armature terminal

3. Generator armature not grounded

Fuel Gauge Erratic or Inoperative

If the fuel gauge operates erratically or not at all, inspect:

1. Loose or broken wire from the constant voltage regulator to the fuel gauge

2. Defective fuel gauge

3. Loose or broken wire from the fuel gauge to the tank sending unit

4. Defective fuel tank sending unit

5. Poor ground connection between the fuel tank and vehicle body

Temperature Gauge Erratic or Inoperative

If the temperature gauge fails to operate correctly, check:

1. Loose or broken wire from the constant voltage regulator to the temperature gauge

2. Defective temperature gauge

3. Loose or broken wire between the temperature sending unit and gauge

4. Defective temperature sending unit

Fuel and Temperature Gauges Both Erratic

If both gauges operate incorrectly, inspect:

1. Loose or corroded constant voltage regulator ground

2. Defective constant voltage regulator

3. Broken or loose wiring from or to the voltage regulator

Because both gauges share the same voltage regulator, failure of this unit can affect both instruments simultaneously.

Proper inspection and electrical testing will help identify the defective component and prevent unnecessary parts replacement.

Safety, Copyright and Source Notice

Safety Disclaimer
Working on motor vehicles involves mechanical, electrical and chemical hazards. Always ensure the vehicle is safely supported, the engine is switched off when appropriate, and suitable safety equipment such as gloves and eye protection are used. If you are unsure about any repair or maintenance procedure, consult a qualified mechanic before attempting the work.

Source
Information compiled from period factory service literature.

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