whiplash1@rochester.rr.com

About a month ago my original (116000mi.) switch started smoking and melted closed. I replaced it with a used one that lasted a month and it smoked and burned out. I bought a new one and within 10 minutes it stated smoking and the pins on the connector were hot. Anyone have any ideas , similar problems or solutions?
Thanks ahead of time.

CurtP

There's a short somewhere. You'll probably will need to strip back the harness wrap and trace the wires from the switch to the PDU.

You should do it soon too. When I started digging in the dash of my car, I discovered that it had a dash fire at one point, which looked to have started at the headlight switch.

whiplash1@rochester.rr.com

I case anyone else experiences this, it was discoverd the inadequate wiring to one of the taillights fused some wires together and shorted things out.

Mello

also sounds like the someone replaced the fuse with one that's too high. I had headlights that blew fuses, until I put in a higher fuse and it melted the switch just like yours.

Travis - sflraver

This happens all the time. All of the headlight current goes thru the headlight switch. As the wires get old, or you put in higher wattage bulbs, the amps that travel thru the switch rise. We created a headlight wiring harness that takes all the current out of that swithch to solve this problem.
Now, I am not just hacking product here... but it is your solution. The switch will catch your dash on fire without attention. Do a search.