healights switch connection

[nonglossjason]

It just melted to the headlight switch, what would cause this and how do i fix it?

 

[jrichker]

If you have foglights, here is the answer:

SEE http://www.corral.net/tech/maintenance/foglights.html to fix the problem. The stock wiring isn't up to the job and is overheating. The headlight switch & turn/multifunction switch are affected by Ford's wiring problem. Sometimes it overheats so badly that the plastic shells of the wiring connectors start to melt. This will show you how to add a relay to the fog lights to relieve the overload on the headlight wiring.

 

[nonglossjason]

Thanks jrichker thats a big help but where can i pick up another one of these pieces that is not melted?

 

[302RollinHard]

junk yard should have something......

 

[krafty]

I got one from CJ Pony Parts...cost like $15

 

[4G-KDMP]

not trying to jack your thread nonglossjason.
but i've been read more and more about headlight switches burning up lately, is this something that eventually all head light switches do, and something I need to worry about?

 

[HISSIN50]

I'd also trace the harness down a ways to see if any started to melt.

4G, cars with fog lights (and no retrofitted fog light relay) are more prone to it. This is one reason that Jrichker and I use relays on all of our forward illumination (lows, highs and fogs). The most current we run through our switchgear is 1 amp or so.

 

[4G-KDMP]

once more nonglossjason; believe me i'm not trying jack your thread..

thanks... HISSIN50 for the facts and what i need to be watching out for.
so if i understand what you're saying .......as long as i don't have fog lights oem or aftermarket fog lights I shouldn't be worried about my switch burning out?
but i'm lost with what you said about the 1amp switchgrear?

 

[HISSIN50]

once more nonglossjason; believe me i'm not trying jack your thread..

thanks... HISSIN50 for the facts and what i need to be watching out for.
so if i understand what you're saying .......as long as i don't have fog lights oem or aftermarket fog lights I shouldn't be worried about my switch burning out?
but i'm lost with what you said about the 1amp switchgrear?

There have been reports by the LX guys where they had headlight switch and wiring issues, but they seem to be much fewer and farther between. The fog light circuit is an extra 5-10 amp (I cant remember the oem bulb wattage) burden on the headlight circuit, hence why GT's have the issue so much worse.

Don't worry about the 1 amp comment. The way we wired our lights, we don't pass any current for the forward-lighting through the headlight or multi function switches. This helps the switches and wiring last longer (that's why I did it - that crap is pricey). If someone isnt very good with wiring (which I dont pretend to lump myself in with JRichker, but I can generally hold my own), I dont recommend doing this because a wiring issues can result in no headlights. This could be dangerous.

The fog light rewire is cool because it helps the most overall and if there's an issue, who cares if the fog lights turn off.

 

[4G-KDMP]

thanks HISSIN50.

i think i've now got a better understanding of what you're saying.