After having two Gen 2 headlight modules go out on me in as many years, I decided to pop the cover off one of them and take a look inside. What I found on BOTH modules was a burnt wire in the relay in the center of the circuit board.

I searched out the relay, ordered it, installed it. The modules work like new and at a cost ($11.54 from Newark Electronics) far less than a new one or even most used ones if you're lucky enough to run across one at the boneyard .

If you're handy with a soldering iron, it's a simple matter of removing the bad relay & replacing it with a new one. Before you toss that old module, take a look at the relay. Chances are good that's the culprit.
Here's the link:
http://www.newark.com/omron...pco-12vdc/dp/42M2371

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Great information. Thanks

Exept...

quote Availability: 0 In-stock Farnell Direct Ship products will ship from UK in 5-7 business days to destinations within the continental United States. A $20 per order service charge applies for all Farnell products in lieu of a freight charge.Farnell UK Direct Ship - Non-Cancelable/Non-Returnable Handling Fee $20 per order Lead Time 86 days Price For: 1 Each Minimum Order Quantity: 1 Order Multiple Quantity: 1 Price: $11.54

$20 fee plus 11.54 part? Ship from UK?

Try Digikey or Google Omron & part #. Omron is common at many E part dealers.

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Dr. Ian Malcolm: Yeah, but your scientists were so preoccupied with whether or not they could, they didn't stop to think if they should.
(Jurassic Park)

The Ogre's Fiero Cave (It's also at the top and bottom of every forum page...)

I've purchased a few Omron relays from my local electrical supply store. Also, you can check Radio Shack, sometimes they stock a useful variety of relays.

@ Ogre: Admittedly, I got mine at a local electronic store but I wanted to post a link to a source anyone on PFF could access. I guess I didn't read it closely enough....my bad.

The info STILL stands though!

Datasheet Archive First listed. If you like datasheets.

Use search- omron MY4 02 12DC

Yes. Good data.
Other post has pictures but is hard to read part #.

Note... Relay is only use to switch forward/backward direction. Main "switch" is the MOSFET.

I've added it to Cave article. Gen 2 headlight motor.

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Dr. Ian Malcolm: Yeah, but your scientists were so preoccupied with whether or not they could, they didn't stop to think if they should.
(Jurassic Park)

The Ogre's Fiero Cave (It's also at the top and bottom of every forum page...)