Headlight switch blues 😬

Is there a relay on the light switch circuit? The relay does reduce the load on the headlight switch, which in turn prevents damage to the plastic tab inside of the switch. What you are describing sounds like a damaged internal plastic tab due to heat. If you have headlights that are a higher output than the factory lights, then there is an increased load on that circuit, which puts more load on the light switch. I installed a relay on my headlight switch years ago, but still had a switch failure. Perhaps I didn't wire the relay correctly. The failure occurred on a narrow winding road at night, which does get your attention when the headlights go out and the headlight doors begin to close. I later installed an old fashion metal generic push pull light switch and never had another problem. I am sure that someone here has a better idea than I do.

@jffr posted:

….. I later installed an old fashion metal generic push pull light switch and never had another problem. I am sure that someone here has a better idea than I do.

That is exactly what I am going to do as well…. Those switches seem to last!
At this point I think it is a good idea! 👍

Can you post a pic how yours looks?

I have had my switch apart 2 times trying to fix the thing.  If you have ever looked inside, it's a small mousetrap of  hanging contacts on little springs which makes your eyes water.   Aside from the stock originality, it should be thrown in the trash and replaced with a reliable dual position switch.  I baby mine at the moment.  

@panterapatt posted:

I have had my switch apart 2 times trying to fix the thing.  If you have ever looked inside, it's a small mousetrap of  hanging contacts on little springs which makes your eyes water.   Aside from the stock originality, it should be thrown in the trash and replaced with a reliable dual position switch.  I baby mine at the moment.  

I chopped #1 up to build my volt meter..😜

The original OEM were not great, I have been through many. And not just the headlight, all of them are crap. I am told that today's replacements were sourced by Wilkinson who supplies them to all of the various vendors.

If you do not care about original appearance. I would highly suggest you consider purchasing from Pantera electrical genius, Jon Haas. Like all of his products, over engineered to work far better than OEM and last forever.

de tomaso Pantera rocker switches (pantera-electronics.com)

I installed relays and bought one from Wylkinson, it only worked on position 2, they sent me another one under warranty, it works fine on position 1 and every other time on the position 2 .........

rene4406 I have the same issue with the Wilkinson switches.

Those switches are 💩