Bi-Pass the Headlight Fuse Block (1960-64)

Bi-Pass the Headlight Fuse Block (1960-64)


If you own a 1960-64 Falcon and have ever had to replace a fuse you may be interested in bi-passing the fuse block on the headlight switch. Other than the difficulty in accessing the light switch, the ignition switch and the new mounting location, this is not a difficult task.

Parts List
Buss ATC Fuse Panel
Assortment of ATC Fuses
15 amp ATC inline fuse holder
Assortment of wire
Assortment of terminals
Heat shrink tubing

Tools Needed:
Soldering gun
Terminal crimper


Removal of the light switch.
1. Disconnect the battery
2. Remove the instrument cluster first, it will make it easier to remove the light switch. As you remove the cluster make a diagram of where each wire connector and bulb holder belongs. Make note of wire colors as an assist for reinstallation. The speedometer cable will also need to be unscrewed.
3. Remove the light switch by first removing the knob, this is done by depressing the release button on the bottom of the light switch. The release button is located under the dash on the side of the light switch (a real pain to find by Braille)
4. Unscrew the light switch bezel retaining nut. There is a special tool for its removal, but I have success removing it with the tips of needle nose pliers.
5. Pull the light switch away from the dash and down. There are two clips that hold the fuse panel to the light switch, pry them off and carefully separate the fuse panel from the switch.

Light Switch Fuse Panel Modification
1. Remove all the fuses.
2. Carefully remove (or cut) the Black-Green wire from the fuse block. This is the wire that supplies power to all the accessories. The Black-Green wire will need to have an extension wire added and a ring terminal placed on the other end. This wire is what will supply power to your new fuse block.
3. All the lights are protected by the fuse marked "PRK-REAR-DOME". You could leave this fuse as is, but to make fuse replacement easier now is a good time to replace it with a 15-amp spade fuse. Solder each end of a 15-amp inline fuse holder to each terminal of the original glass fuse holder. When you reinstall the light switch, position the inline fuse holder below the light switch (easy reach).

The New ATC Fuse Block.
1. Mount the ATC fuse block above the driver's side kick panel. A couple of sheet metal screws will hold it in place (it may be near impossible to drill holes with the driver's side foot vent in place, I removed mine)
2. The Black-Green wire from the original light switch attaches to the power supply lug.
3. The Orange-Yellow wire (Directional Signals) will attach to one of the spades, use a 15-amp fuse (blue). The original fuse was 14 amps, but 14 amp ATC fuses are not available. You may need to add an extension wire to reach.
4. Attach the Brown wire (Heater), use a 15-amp fuse.
5. Attach the radio, 7.5-amp fuse.
6. Add any new accessories you may have.
7. Re-connect the battery and cross your fingers, hopefully you will not release any smoke.

Note: I moved the wiper motor (Orange - White) from the "A" terminal on the ignition switch to the new fuse block. The wiper motor is protected by a circuit breaker either in the wiring harness or the switch (year dependent). Of course, if you still have vacuum wipers this does not apply.

Tips
• Take out the front seat, it will make life easier.
• On my Ranchero, I added a similar fuse block above the passenger side kick panel for non-switched accessories (always on). I ran the power supply to the fuse block from the solenoid using a 20-amp fuse inline fuse holder at the battery side of the solenoid.