Why do the headlights on my Mazda Navajo shut off while driving?

Short answer: Headlights that go off and on after 20 minutes of driving on a Navajo usually point to the headlight switch tripping its built-in breaker because it's overheating, or a worn dimmer switch on the column. The Navajo is a two-door version of the Ford Explorer, so Explorer switches and repair guides apply. A gooey steering wheel is the original foam padding breaking down in heat.

Symptom: The headlights cycle off and back on after you've driven a while, the dash lights dim, or the steering wheel feels sticky.

What to check first

1. Note how long you drive before the lights cut out.
2. Feel the headlight switch knob after a drive. A hot switch is a clue.
3. Try flash-to-pass and high/low beam to see if moving the stalk affects the lights.
4. Check the headlight connectors for melted or brown plastic.
5. For the steering wheel, a cover is a short-term fix. A replacement wheel is the long-term fix.

Likely causes

1. Headlight switch overheating. The headlight switch has a built-in circuit breaker. If the switch is worn and gets hot, the breaker trips and the lights go off, then come back as it cools.
2. Dimmer / flash-to-pass switch on the column. The stalk that switches high and low beams can wear out and cut the headlights.
3. Foam steering wheel padding breaking down. Fords of this era used foam padding in the wheel that can turn soft and gooey in heat.

What it usually costs

Owners in these threads didn't post prices.

Is it safe to keep driving?

Headlights that cut out at night are dangerous. Avoid night driving until it's fixed.

DIY or shop?

Swapping the headlight switch or dimmer switch is often DIY with a basic guide. Replacing the steering wheel is a bigger job, so a shop may be the better choice.

Recalls, bulletins and complaints in plain words

• Recalls: NHTSA lists 9 recall(s) for the Mazda Navajo in these years, and none match this problem. Check your VIN at nhtsa.gov/recalls. If your car is part of a recall, the dealer fixes it for free.
• Plain words: The complaint count below shows how often owners reported problems that mention these words to NHTSA. A count is not proof of a defect.
• NHTSA complaints: 3 keyword-matched complaints for Mazda Navajo 1991–1994 (of 129 unique complaints queried, NHTSA complaints API by model year, queried 2026-10-29; keywords: headlight, head light, lights, dimmer, steering wheel). This counts complaints that mention these words. It is not a defect finding.

What owners report

• In 92 Mazda Navajo headlight issues on Car Talk, a '92 Navajo's headlights cycled off and on after about 20 minutes of driving while the panel lights dimmed. Members suspected the headlight switch or the dimmer/flash-to-pass switch.
• In To: Bill from Sacramento, 92 Navajo's Oozing Steering Wheel on Car Talk, a '92 Navajo's leather steering wheel was oozing. The reply explained that Ford used foam padding in that era that can melt in heat, and that tape is only a short-term fix.

Quick tip

The Navajo is basically an Explorer, so shop Explorer parts. You'll find more choices and better prices.

Vehicle focus: Mazda Navajo two-door SUV, 1991-1994 (built by Ford alongside the Explorer).

Safety / mechanic note

Lighting is a safety item. Verify with a mechanic.