Question about 1991 Mitsubishi Montero
I recently had to disconnect the horns on my 1991 Montero because they suddenly became stuck on. I suspect a stuck relay, however, I cannot find any information on its location. The Haynes repair manual doesn't even show a circuit diagram for the horn circuit. I had no luck finding the information on the internet either. Is it possible they may have designed a horn circuit that does not use a horn relay?
Although the Haynes repair manual did not have an electrical diagram for the horn circuit, I suddenly remembered I had an old CD-ROM based Auto Repair program from Popular Mechanics that has an extensive selection of diagrams. It did have a diagram for the horn circuit which showed that there was no horn relay in the circuit. So I started by taking apart the horn button on the steering wheel. The horn button is a switch consisting of two metal discs approximately two inches in diameter which are separated by a thin layer of foam which is supposed to keep the two discs separated. The metal discs have dimples that should be kept apart by the resiliency of the foam but when the foam is compacted, the dimples come together to complete the circuit. However, the foam had deteriorated to almost nothing and was allowing the two discs to be in constant contact. I solved the problem using picture hanging tape. This is a double-sided adhesive tape that is about 1/16 inch thick and comes in a roll and can be found probably anywhere hardware is sold. I cut the tape into small squares and stuck them to strategic points on the flat parts of one of the discs so that they would keep the discs apart with approximately the same resiliency as the foam. When external pressure is applied to the outer disc, the dimples come together just like before to complete the circuit and the horn works perfectly.
One thing I would like to point out is that when I initially took the horn apart, I started by removing the outer soft rubber cover from the horn pad to expose the horn button. It came off easily, but when it came time to put it back together, I could not get the cover back on. Then I discovered that there are three phillips head screws on the back side of the steering wheel that hold the horn button assembly in place. So to save time and frustration, I would recommend that step one be to remove those screws first.
Posted on Jul 21, 2008
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