Headlight switch worn or melted?

[BartusCompater]

When I go to turn on the headlights by putting my switch into the third position from second, the running lights will switch off unless I actually press the switch into the dash like a button.

After inspecting the switch itself it appears to be either melted or just worn down. Two spring mounted pegs seem to be responsible for depressing two little metal strips inside to make a connection. With the pegs worn down as they are they must not be pressing the little strips down enough to keep a connection in the third position.



I'm wondering if this is a common problem and/or if these pegs have been melted or if they are just worn down from rubbing up on the strip for 30 years. Should I just replace the switch or do I have an underlying electrical problem that I should be looking for? It certainly looks like it's been melted, and I noticed that the little block that retains the wires that the switch connects to has a little portion that is scorched at one of the wires.

[ORFORD2004]

For me the best solution will be to try to find another one but you can also put some epoxy at the end of the worn pegs. That can be a cheap solution

[Danq]

My head light switch had the same problem. On mine only one of the "pegs" melted. Also one of the contacts on the connector block showed evidence of over heating. I got a new switch from VIc's for about $15. I put a headlight relay kit to improve the light output from the headlights. This way the current for the headlights doesn't flow though this switch, just current operate the headlight relays. The switch in the stock configuration barely handle the current required by the lights. Add in a few bad connections or auxiliary lights and the switch overheats and starts to melt.

[BartusCompater]

Thanks for the quick responses... Danq, that was the response that I needed to hear. I'm glad I didn't just order a switch and leave it be to melt again. Where did you get your headlight relay kit from? Was that also from Vick's?

[Danq]

The relay kit was from IAP.
I liked the kit because the original wiring was not modified. I did change two things from the instructions. I removed the original headlight plugs from the buckets because there was just too much wire for the lights to seat. there are metal tab on the body to put the plugs. I ran the grounds from the new light plugs to the ground blooms on the inner fenders. I pulled fuses D and F to kill the right headlight plug.
The kit uses the left headlight plug to control the relays.

[BartusCompater]

Is this the kit that you got?

http://www.international-auto.com/light ... de-kit.cfm

[Danq]

Thats the one