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'05 Saab 9-5 Aero Wgn - headlamp issue
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Posted by eshaw [Email] (more from eshaw) on Wed, 27 Aug 2025 11:34:50 Share Post by Email
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So I had my driver's side headlamp fail. The headlamp failure warning light would intermittently come on. Before replacing the bulb I had a strange experience driving home at night (one headlamp and fog lights on) and (I believe) when I switched to highbeams or back all my lights went completely off and then I did the opposite and they came back on. Figuring this was potentially a fuse issue I pulled the fuse (it was extremely tough to get out) and it was not just blown but scorched. I replaced the fuse and then pulled the headlamp bulb to discover it was literally broken. I replaced the bulb and shortly thereafter had the warning lamp come on and it has at least a few times been intermittent with the headlamp working occasionally but now it isn't working again.

I brought the car into my mechanic for a brake job and asked him to check the headlamp issue as well. He has been a Saab guy but is certainly no longer a specialist if he ever was one. He tried to troubleshoot the issue and this is what he said after spending about 4 hours on it:

He said he traced the issue to the violet wire going to the headlamps - passenger side has power to that wire coming from the same terminal but the but the driver's side does not. He also reports the Positive terminal on the battery is getting too hot to touch. He's thrown up his hands (he's not billing me for the time spent troubleshooting) and said that If someone had the wiring schematics or the expertise they could probably pinpoint the issue easily. He said he thinks it's likely a ground issue but he did check and resecure the known grounds for the lights, but that he didn't want to start taking everything apart looking for the problem.

Does anyone have any suggestions? I do have a Saab specialist I can try but he is very hard to get an appointment with. Any thoughts or input appreciated.

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