Horn Repair

[mudrunner88]

Having issues with your horn? If it only honks sometimes or sounds weak at times you may need to get a horn repair kit.




To learn how to inspect and replace your horn contacts that are worn out please continue below.

CAUTION: Be sure to disconnect your battery or pull the fuse for the horn before continuing.




The First thing you want to do is remove the steering wheel cover. On the SR5's there is a single screw in the center of the bottom area behind the steering wheel. On the others there is two screws on either side of the steering wheel behind the horn buttons at 5 & 7 O'Clock. Go ahead and remove the screws, then gently push up and pull out at the same time.


Next you gently pull the single horn wire with the spade fitting off the steering column. Wire may be lower to the bottom for the non-SR5 models.


Get yourself a ratchet with a 19mm socket and break the steering wheel center nut loose. Back it off all except about 2-4 threads...Now grab the steering wheel at either side and rock it back and forth while gently pulling. The steering wheel should slide out and hit the nut. Remove the steering wheel.


Here you see a photo of the combo switch, the horn contact is in the upper left corner.


This is a photo of an old and new horn contact.


Now you need to decide on a quick fix or permanent. If your in a jamb and just need to do a temp repair you can flip over the steering wheel and you have a horn contact ring held in by three screws. Simply remove these screws and stack some washers behind the ring and reinstall the screws. This will cause the contact ring to be closer to the spring loaded contact and hopefully make contact again. If needed run some light sand paper over the spring loaded contact to clean it up a little. Now put it all back together and the horn should work temporarily until the horn contact is extremely worn out.


If you are replacing your horn contact the next step would be to remove the column covers as shown...I noticed some have six screws and others had eight screws. It does help if you have tilt steering but it's still possible without it.


Now that the covers are off you can push the horn contact in and look down the top and see the single wire attached to it. Go ahead and remove the wire and the tiny c-clip that holds the horn contact in place. I used a small flat head for this step and partially pushed the clip off, then I spun the rod around to carefully squeezed it out with needle nose pliers. Now simply slide out the old contact.


You may want to stretch out your spring a little bit before you slide it onto the new contact if it didn't come with a new spring.


Add some good lithium grease to the rod and it's cylinder it slides into. You don't need a lot, you are just preventing it from sticking as it wears down again.


You should be able to now re-install the new horn contact and insert the c-clip. It's a tight spot to get the clip on. What I did was put a dot of grease onto groove for the clip. Then take a small flat head screwdriver and put a dot of grease on the very tip and stick the c-clip to that. Carefully lower the clip down onto the rod (you need to push in on the spring loaded part as you do this). Transfer the clip from the screw driver to the contact rod being careful not to drop it. After you position the clip use the screwdriver to push down on the top of the clip and lock it in place. If you have small needle nose you can use those as well but it's a tight spot. Now re-connect the horn wire to the rear of the horn contact.



In this photo you see the horn ring on the back of the steering wheel. If your ring seems to be dirty go ahead and clean it with a pencial eraser

When you are satisfied go ahead and re-assemble. Don't forget to re-install your fuse or battery cable.

Enjoy your new honk!.



Recently I called my local dealer for the horn contact, they stated they are $8.00 but can longer be ordered. I'm sure somewhere in a warehouse they must have them so I would check with your local dealership first.
Since I couldn't find one at my dealer I visited the junkyard and found a nice looking truck and scored what looked to be a new contact and they gave it to me for free since I bought a few other things

Another user suggested this kit on Napa. http://www.napaonline.com/masterpage...act+Repair+Kit It looks a little short but if you are crafty I'm sure you could adapt it somehow. I was wondering if we could cut these down and bond or solder it to our worn out contacts some how. If anybody attempts that take photos and we will add to the thread!