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Date:         Thu, 25 Feb 1999 06:09:09 PST
Reply-To:     Mark McCulley <transporter99@HOTMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Mark McCulley <transporter99@HOTMAIL.COM>
Subject:      Re: Headlight switch failure (possible solution)
Comments: To: KENWILFY@AOL.COM
Content-type: text/plain

>I unplugged the switch and somehow it had >overheated and melted the plastic on the back of the switch which cocked the >plug on the switch so it did not make proper contact. > I really think the solution to the headlight >switch problem (and also a way to get brighter headlights) would be to install >a headlight relay. This will take the load off of the switch (which obviously >can't handle it) and put it on the relay (which is made to take the current).

Headlamp switches often overheat as the result of corrosion-induced resistance on the switch contacts. Over time enough resistance builds up to cause not only a significant voltage drop but also generate enough heat to deform the plastic switch housing. This phenomena can also occur on a relay--anywhere you have a relatively high current passing through a spade lug connection. The best preventative fix is to clean the spade lug connections and ensure they provide a good electrical connection.

MM

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