Hello, I have an 1987 5000CS Quattro Turbo in very good condition, and the headlights just stopped working one morning. I checked the fuses and even went as far as purchasing one new headlight just to make sure. The strange thing is that if I hold the high beam switch manually on the directional arm the high beams will work. I purchased a headlight relay (DNI 1027) from rockauto and can't seem to even find its location. I'm guessing that it's probably the combination switch on the steering column itself. On the first click of the combo switch the running lights all come on, but when click to the second final stage for the headlights they do not come on. Any help would be greatly appreciated.

 

If you have Hi beams but no low beams, it's most likely your switch. email Chris at Force 5 Auto ( chris@force5auto.com ). I got mine from them, only ran me about $20 bucks. I just haven't installed mine yet, I haven't gotten the chance to get the steering wheel pulled off.

 

Ripo, thanks for the information pertaining to Force 5 Automotive. I have recently been in contact with Chris in regards to the failure point; the combination switch, and will purchase a used one soon. After some further research I'm almost convinced that the headlight relay switch (DNI 1027) doesn't exist for the turbo version that I own. I wanted to swap it out with the original one since it's new, but after calling numerous shops and looking in Haynes and Bentley manuals I can't seem to find its location. When I bought the headlight relay, it was supposed to be for my Audi, so I thought.

Thanks again!

 

Take it from me. Rockauto sucks. I bought an alternator from them for my 200QT, and it was the wrong part. called them back after 31 days (it took that long to find out it was the wrong one), and they said they weren't accepting the part back, and even if they were, I would have to pay the shipping and a re-stocking fee. So it doesn't surprise me in the least that they sold you the wrong part. I would just stick with Force 5 for parts, or if you're in a bigger city, check the local junkyards. You might be able to find a 5000CS, or a 200QT, both of which should have at least some parts you could use. I know some parts from the 200 20v will work on my car, and the 5000CS is pretty identical to mine from what I've heard, so that would be my advice.

 

As already mentioned it's the switch which is a real weak spot, because the whole current for the headlights (approximately 7 amperes) is flowing through two little copper contacts in the switch.
I had the same thing at my 88s Coupe last week. I opened the switch and bended the worn contacts a bit.

The best solution is to use additional relays (one per side) to supply the headlights directly from the battery. The original cable coming from the switch only activates the two relays so that the switch is disburdened.