2003 HILUX HAZARD SWITCH MOD

Discuss modifications on your late 1998 to 2005 IFS Hilux here.
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JAMES399
High Range 2WD
High Range 2WD
Posts: 12
Joined: Tue Jan 24, 2017 3:21 am
Town: Alejandria Antioquia Colombia SA
Vehicle: Toyota Hilux 4x4
Real Name: JAMES

Sat Dec 30, 2017 6:40 pm

The right hand directional signal stopped working on my 2003 Hilux, so
started looking for the problem. Checked out everything and found
that the hazard switch was the culprit. With the switch removed and
jumper wires installed to simulate being in the Flasher “OFF” mode,
the RH turn signal began to work.

My truck is fitted with a dual-fuel conversion (gasoline or compressed natural gas). The location of the gas/CNG selector switch and fuel level indicator (lower left hand side of the dash) was hard to see. The hazard switch cutout was a much better location. The rear window defogger switch cutout was a perfect location for a new hazard switch

A factory replacement hazard switch costs 285,000 Colombian pesos (about $95 USD). Being a cheap-ass, I decided to replace the stock switch with an on/off switch and a relay.

After checking out the Hilux Hazard switch circuit, it looked like a 4PDT relay would work.

The parts:
switch.jpg
switch.jpg (9.71 KiB) Viewed 74 times
1.) SPST red hazard switch w/led (Ebay - $4.95/free ship)
2.) 1N4001 diode
3.) 4 pole double-throw relay with 12v coil
4.) Hookup wire and double-sided sticky tape.
5.) 1/8” male solderless connectors

Drew up a connecting diagram.
hazard switch conn diagram.png
I wanted to retain the original hazard switch plug and not have to cut
up the factory wiring harness. Soldered wires to the contacts on the
original hazard switch, and used it as a jack to connect to the wiring
harness plug.

The completed relay and switch assembly.
relay assembly.jpg
relay assembly.jpg (12.16 KiB) Viewed 74 times
Installed on the rear of the dash panel
instsllrelay.jpg
The final installation.
IMG_20171228_115109.jpg
The CNG/Gasoline selector installed in the original hazard switch location below the clock, and the new hazard switch in the rear defogger location

This was an easy mod, and it worked perfectly. I put the switch and
relay assembly together on my bench, and installing it was simply a
matter of enlarging the switch cutout slightly and then plugging in
everything. Total cost of parts was 24 000 COP ($8 USD). Project took
about a week from start to finish. Well worth the time.

- JAMES

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Mud Dog
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Joined: Tue Apr 29, 2008 2:18 am
Town: East London
Vehicle: '90 SFA Hilux DC 4X4, Full OME, 110mm lift. Brospeed branch, 50mm ss freeflow exhaust. 30 x 9.5 Discoverer S/T's on Viper mags. L/R tank. (AWOL) '98 LTD 2.4 SFA, dual battery system. Dobinson suspension, LR tanks, 31" BF mud's.
Real Name: Andy

Sat Dec 30, 2017 10:28 pm

Well done James! :thumbup:
With a little savvy, some know-how and the will to do it, the possibilities are almost endless and you've harnessed those qualities to sidestep a dealer OEM spares rip-off and perhaps even improve on the original layout (for your needs anyway). Thanks for sharing. :winkx:
When your road comes to an end ...... you need a HILUX!.

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Don't take life too seriously ..... no-one gets out alive.
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