I need help with this can you guys point me in the right spot to start on this problem. I dont have a clue where to look first. Thats why I cant go the track tonight and run.
The light switch has a circuit breaker that opens when there is too much current. When it cools it resets automatically. That is why they go on and off. Did you add Halogen headlamps or any other auxiliary lights to the circuit?
If not, then it is probably just the switch getting old. It would help to clean the connectors at the headlamps and check the wiring for cracks or signs of too much heat. Also check the Dimmer switch for the same thing.
If that doesn't help then here is your light switch:
More than likely it's your headlight switch... just too many amps drawn through it over time. A quick fix is to pick up a headlight switch for like a 67-68 couger that had the quad-headlights. These are rated at a higher amperage than the normal stang ones.
The relays are also a good idea.. you can buy the painless kit or make your own using generic 5 pin DBDT (double pole, double throw), or 'Bosch type", relays. (Autozone pn# MR76 or MR78 depending on if you want a mounting tab or not)
Wiring is simple... find the two wires from the switch that turn on your headlights and highbeams. Cut said wires, these will now be used to turn on the relays instead. You can wire one wire directly from the battery or a similar 12V source and then branch it off to two relays. Each of the relays will have a ground, and the wires that used to power the lights will now feed switching power to the relays and you can re-use the wire going to the lights on the other side of the cut to power the lights as the 'power out'.
Wiring goes like this.
Pin 30: B+ (battery power)
Pin 87: Power out
Pin 85: Ground
Pin 86: Switched power (from headlight switch)
Don't forget to put a fuse in as well, i believe a 30a is normally used.
You can also check out BCbroncos website for a very helpful diagram.