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2nd Gen Non-Engine/Transmission headlight switch smelling bad and fixed

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Engine/Transmission (1998.5 - 2002) Rubber Boots

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About 3 months ago I noticed the headlights hesitated when I turned them on. I checked tdr and found the threads about the melting wire block at the back of the headlight. All was good until two days ago when there was an obvious burning smell and while traveling 65 down a wooded 2 lane road at night the lights went out. Talk about getting my attention. I managed to get the lights back on.



I was ready and armed due to this forum. I visited the stealer and bought his $98 light switch and wire block, cut out the old block, spliced in the new and all is ok. I also followed the advice of someone here to drill a hole in the ac duct since the wire block is immediately above it. I went a little further by sawing two slots starting at the hole for about one inch which made a plastic tab. I then bent the tab down to make an air dam diverting a small amount of cold air directly on the wire block. Now when I ride with the ac I can feel the base plate of the light switch on the dash and it feels cool to the touch.



I have 123,000 miles before it went. Hopefully this will keep me away from Mr. stealer a bit longer.

Oo.
 
BA, Just installed the Sport lights and put two of the wiring packages in (they go to batteries with there own relays), now the headlight switch only turns on the relays... you may want to look at this for long term--you would only need one wiring kit for your stock unit... ... ... ... . my 2 cents, R, J. B. ;)
 
Mine did the same thing last winter. I think they charged me about $60 for the switch and connector kit. You guys should ask for a discount when you buy parts from the dealer. If they won't do it - go to a different dealer.



Blake
 
BA, Just installed the Sport lights and put two of the wiring packages in (they go to batteries with there own relays), now the headlight switch only turns on the relays... you may want to look at this for long term--you would only need one wiring kit for your stock unit... ... ... ... . my 2 cents, R, J. B.





where do you get the wiring packages and are their installation directions?
 
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