'Burb Backup Light Repairs
 
So... it's getting dark earlier these days as winter approaches. My backup lights worked when they wanted too. They weren't as bad last year, a good smack on the quarter panel was good for a few days of light. Then they just got too intermittent to put up with anymore. Simple 10 minute repair right? Wrong. The engineers 35 years ago made the fixtures a little different. Here's the cure to the intermittent problem. Why did I put up with them so long? Who knows?
 
 
First of all, the lights are held in by (more than likely) rusted nuts & bolts. I used a pea grinder to get rid of the bolt heads. Then the wire was too short to bring out of the hole. I used hemostats to hold it from pulling back as I cut it off. Then I thought I was going to use a socket repair kit to fix the corroded connector. Well... sorta' The fixture doesn't have enough clearance at the bottom to allow the usual insulator disk, spring, and wire repair piece to fit.
The bulb won't lock in because the original  connector fits way down in the rubber piece, and the repair kit holds the bulb about 1/4" too high to allow the pins to lock in the slot. It's spring rusted into oblivion, and I removed it's remains from inside the brass piece. The spring shown is from a cheap ink pen, and fits perfectly. Get a kit for 1157 bulb sockets, and you will gain the needed two wire pieces. Discard the plastic disk parts. I cut the spring in half to get the length right, then reassembed the socket. Now the bulb locks solid again. Since the old Suburban uses glass lens, I can use special Federal Signal 100 watt halogen light bulbs. A plastic lens would last less than one minute with this bulb before melting into a blob. Notice the tune-up grease. It eliminates corrosion. Try it on your RV bulbs, and you won't have to play the "light bulb game" the next time you hitch it up.
I reinstalled the fixture with self tapping screws to replace the inaccessible nuts & bolt setup. I didn't paint the inside because of the 100 watt bulb's heat. Normal bulbs would benefit from silver of white paint to help as a reflector. You can get 55 watt halogens from some parts houses. Don't get finger oils on the bulb!! Use a tissue paper to install halogen bulbs. Back in the truck, and somewhat tilted due to needing blank sheetmetal for the new screws to grab. They don't look too bad from a few feet away. Love those genuine glass lens! And now, they actually turn on when needed! Use a relay to operate the backup lights if you use high powered bulbs. The backup switch won't handle the extra current draw. Refer to this page for relay help.
 
200 watts of backup light power!!
 
 
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