Replacement for Meyle dimmer relay

Dangerous Doug · #1 (**permalink**) 09-28-2009, 05:21 PM

I don't know if any of the rest of you have run into an issue with the Meyle 100 941 0006 dimmer relay. I had a problem with mine in which the headlights would not work predictably. Flicking the dimmer, sometimes they'd switch correctly (low to high, high to low) and then sometimes they'd just go completely off by flicking the dimmer switch.

A little alarming, to say the least, to be cruising at night and flick the dimmer expecting to go to high beams and they just switch off...

ERA was great, in that they willingly replaced the dimmer relay for me...twice. However, all three of these Meyle relays did some variation along the same lines. I took one apart, and the design flaw is in a tiny metal blade that doesn't always bent predictably, and this blade is used to flip a mechanical switch back and forth.

Anyhow, after quite a bit of fruitless effort to find a non-Meyle replacement (I was just about to design my own using power FET's...) I found the replacement part that works great.

I found it at a vintage VW site called www.airheadparts.com.

Part number is VW 111-941-583. This is a direct replacement to the designed in by ERA. Price at my time of purchase was $64.37. Not cheap, but cheaper than the heart attack that Meyle relay was going to give me.

Thought I'd pass on the tip.
DD

tkb289 · #2 (**permalink**) 09-28-2009, 07:30 PM

Doug,

Thanks for the tip ... I'll keep this in mind when I put my car together.

Also ... congratulations on post # 1001 ... you are now in the 4 digit club

- Tim

patrickt · #3 (**permalink**) 09-28-2009, 07:42 PM

Quote:

Originally Posted by Dangerous Doug

Part number is VW 111-941-583. This is a direct replacement to the designed in by ERA. Price at my time of purchase was $64.37. Not cheap, but cheaper than the heart attack that Meyle relay was going to give me.

When did ERA switch to the Meyle? I thought the VW, a shot of mine is below, was standard ERA issue?

Dangerous Doug · #4 (**permalink**) 09-28-2009, 08:10 PM

I bought my kit about four years ago, and it came with the kit. When I got #2108 running back in November I found the problem. ERA replaced the relay twice, but both times with the Meyle. After taking one apart and identifying the mechanical issue, I decided to find a non-Meyle part.

No biggie. I have predictably operating headlights now. I'm happy. Well, after I swap out that tach...

DD

PS: Tim, I am having a great time driving my FIA around. I'm over 3k miles since I got it running last November! It's already time for my first oil change.

patrickt · #5 (**permalink**) 09-29-2009, 05:20 AM

Quote:

Originally Posted by Dangerous Doug

I am having a great time driving my FIA around. I'm over 3k miles since I got it running last November! It's already time for my first oil change.

Then it's time to check the small set-screw on the clutch throw-out arm. It can vibrate loose and the arm will fall off the spline resulting in the clutch pedal going all the way to the floor and stranding you. I wrote about this a year or two ago. A quick search will bring it up along with other ERA owners saying "Dang, my set screw was loose too, glad I read this thread!"

strictlypersonl · #6 (**permalink**) 09-29-2009, 05:44 AM

Unfortunately, our source for the relay no longer is able to supply the steel-cased version (which I think came from Hungary). The Meyle unit comes from Germany, so you'd think it would be high-quality. But...

Lately I've been checking and tweaking the ones we get so that they test OK, but I'll look around for a reasonably-priced alternative. It seems every time I turn around the price of our imported parts goes up significantly.

marcalan · #7 (**permalink**) 09-29-2009, 10:30 PM

thanks for the heads up, much appreciated

tkb289 · #8 (**permalink**) 09-29-2009, 10:47 PM

Quote:

Originally Posted by Dangerous Doug

I bought my kit about four years ago, and it came with the kit. When I got #2108 running back in November I found the problem. ERA replaced the relay twice, but both times with the Meyle. After taking one apart and identifying the mechanical issue, I decided to find a non-Meyle part.

No biggie. I have predictably operating headlights now. I'm happy. Well, after I swap out that tach...

DD

PS: Tim, I am having a great time driving my FIA around. I'm over 3k miles since I got it running last November! It's already time for my first oil change.

Doug,

Almost a year ... does not seem like that long ... sounds like 3000 fun miles too

When do you send the car off for paint? Or maybe just going to keep it bare for a while longer ???

Looking forward to getting my car ... last I heard they were working on the frame ... time to hurry up and wait!

- Tim

Dangerous Doug · #9 (**permalink**) 09-30-2009, 09:56 AM

Goes up for paint in February.

Bad-ass black.

I can hardly wait. You'll probably be installing your engine by then.

DD

Gunner · #10 (**permalink**) 03-14-2010, 01:34 PM

I need to check/fix/replace my dimmer relay - it appears to have fused the high-beam contacts shut. I've studied both the wiring diagram and the updated connections diagram... and I can't find anything that shows the location of the relay. Can someone tell me exactly where to find the little sucker?

patrickt · #11 (**permalink**) 03-14-2010, 01:47 PM

Quote:

Originally Posted by Gunner

I need to check/fix/replace my dimmer relay - it appears to have fused the high-beam contacts shut. I've studied both the wiring diagram and the updated connections diagram... and I can't find anything that shows the location of the relay. Can someone tell me exactly where to find the little sucker?

Here, it's the square silvery looking box zip tied to my steering column. If it's not zip tied to your steering column, just follow the red and white wires and you can't miss it.

Gunner · #12 (**permalink**) 03-14-2010, 02:00 PM

Ah. Mine's a black Meyle just floating in the wiring, but that made it easy to find. Thanks.

Now to diagnose/fix.

ADDENDUM: Boy, that's one mickey-mouse mechanism. As DD described it, the alternating latching (high to low beam) is controlled by a little metal blade that has to be EXACTLY right, or the plastic rocker won't work right. It's ridiculously flimsy and sensitive, especially for something intended for the rough duty of automotive use.

Hmm. Now to come up with a better solution that doesn't cost $65 (probably for a slightly improved version of the same crummy design...)

Mooch · #13 (**permalink**) 03-14-2010, 02:15 PM

A link referencing patrickt's set screw post as noted above:

Ehhrggg, Standed by a Set-Screw

patrickt · #14 (**permalink**) 03-14-2010, 04:31 PM

Quote:

Originally Posted by Gunner

Now to come up with a better solution that doesn't cost $65 (probably for a slightly improved version of the same crummy design...)

Here's the VW relay for $15. Surely you can spring for that.

http://cgi.ebay.com/ebaymotors/VW-He...Q5fAccessories

H_wingman · #15 (**permalink**) 09-02-2020, 08:36 AM

Well I guess my post with multiple numbers and other info was deleted guess I did something wrong or I am not wanted here ?????

patrickt · #16 (**permalink**) 09-02-2020, 08:44 AM

Quote:

Originally Posted by H_wingman

Well I guess my post with multiple numbers and other info was deleted guess I did something wrong or I am not wanted here ?????

Having only two posts in nine years is not good.