The headlights on my 2006 Mazda3i intermittently do not turn off.

Some googling tells me that:
- The problem may be a bad "relay."
- Flashing my high beams turns off the headlights - for now.

I'd like to get it fixed, but my regular mechanic says the only solution is to replace the entire "fuse block box" aka "fuse assembly," for $650! (The part number is BAN666730F.) This is also what the local Mazda dealer told them.

My mechanics suggest that I live with the high-beam workaround.

Is there no way to identify and replace the individual relay, probably a $5 part?

Second question: how can I identify which other Mazda models may have the identical fuse box, to enable some junkyard-diving?

Thanks.

 

Have you tried checking the headlight relay? I'd try pulling that when the problem happens and see if it turns it off. It's possible that the relay simple isn't unlatching and somehow triggering the high beam relay is breaking it loose. Headlight relays are located in the fuse box in the engine bay by the battery.

 

Yes, it is the headlight relay, which (I think) is in the fuse box under the glove compartment - inside the passenger compartment, not in the engine bay.

The problem is, my mechanic (not a Mazda specialist, but trustworthy) says Mazda is telling them that the relay cannot be popped out and fixed - the entire box has to be replaced for $600+!

Since my last message I've hacked it by flashing the high beams - that turned off the low beams - but tonight, that hack failed, and it took me a while to figure out how to pull out the two headlight fuses - the only way I could see to turn off the lights. (Unscrewing the battery seemed more of a challenge.)

I'm hoping someone can document that my mechanic is wrong, and that the relay can indeed be replaced.

Thanks.

 

I looked into it more. It appears the low beam relays are built into the fuse box.

 

I'd fire the engineer who designed that!

 

^^ No kidding. I mean relays are nice little modular deelies for a reason. I mean sure I've seen hazard relays built into fuse boxes before... then again hazards get used a lot less than headlights.

 

Replacement fuse box purchased on eBay: $30, rather than $650. :-)

Anyone have instructions to perform the swap?

 

Take pictures as you go along tearing it apart and document where all screws and wires came from, this will save you lots of hassle when putting it back together.

 

Are we talking about the box in the engine bay or the PJB in the cabin? I'm pretty sure it's the PJB. If so replacement is easy.

-disconnect negative battery terminal
-look under/behind the glove compt.
-remove the black plastic cover
-turn the two thumb screws holding the PJB up and it will lower
-pull slightly back/down to release the back from the little hooks
-unplug the six large connectors (IIRC two wide, four skinny)
-swap all your fuses over to the new one
-reconnect all the large plugs making certain they're firmly seated before lowering the locking arm
-reinstall in reverse order