Here was the situation... My driving lights were not workin :'( So I look at the light bulbs thinking both might be blown.. Not the case.. So I pull the switch expecting to find my wiring harness burned or something.. Not the case.. So I start to check the switch for connectivity.. Low and behold the switch does not close to turn on the lights.. After staring at the switch wondering what makes up this wonderful piece of hardware I decide to take it apart to see.. Since the lights did not work to begin with, and I was expecting to buy a new swtich I had nothing to lose..

When I get the switch apart I find that a metal band that all the power for the driving lights goes through has come off the back of a PLASTIC rod.. All that is holding the metal connections for the switch are a couple of small plastic nipples.. Given the amount of heat that can be generated by the electricity flowing though the switch it is only a matter of time till it fails..Who in there right mind makes a PLASTIC switch??

After getting over this shock I put everything back together and apply a little heat to the plastic to hold the metal for a little longer. Does anybody know if they make any other switch to replace the stock head light switch given all the wires going in and out of it??

Sorry for the long post..

 

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I had the same problem with mine, looked like burnt toast. Got a new headlight switch from my local dealer. Kinda pricey ,and of course they upgraded the switch because many trucks have had this problem.(recall????? >)

 

The headlight switch is a recall item. Complain!

 

I installed relays on all my lights. No more high current through the switch.

 

same here - relays everywhere.