Seems I don’t get to drive or work with my car much as I’d like to these days and seldom have it out after dark. Last night I did and my headlights failed. The headlights wouldn't pop up and the lights wouldn’t turn on. Even after manually actuating them, when I'd turn the ignition switch, they'd just retract irrespective of headlight switch position. It resulted in a two mile drive home in the dark. I can cross that one off the bucket list.
I’ll spare you all the details but it turns out the headlight switch took a dump. When I removed it from the panel it almost fell apart. They seem to be notoriously fragile from the various threads I’ve read here. While I was troubleshooting, I discovered my headlight door relay was wired very strangely. A couple of the wires fell off before I could get it completely loose but I’m not even sure how it could have even worked (but it had). It had a 12 gauge blue wire that was switched to 12v from the ignition switch with what appears to be a 30A circuit breaker. The breaker was mechanically mounted with one of the headlight relay screws. Why would you need a 30 amp breaker on the headlight motor circuit? I removed it because there was already a 12v supply to the relay. Here’s a picture of the circuit breaker. Anyone recognize this?
I rewired it per the schematic below.
In the mean time I removed the switch and made a jumper for the wires and all is fine now at least temporarily. I think I’ll make the recommended mods to the headlight circuit such as others have done and described my Mike Drew here to add a couple relays and get the headlight current of the switch.
I see the vendors have replacements. So does anyone have a spare headlight switch for sale with chrome bezel and ‘LIGHTS” script like this one?