Headlight Switch

[Bob Beauchaine]

I replaced my headlight switch on 11/17 and did some modification to make the job easier in the future. After removing the instrument bezel and the headlight switch cover I couldn't see any sane way of disconnecting the old switch from the connector. I pulled out my trusty old die-grinder an cut away enough of the inner dashboard to pull the switch from the front. From there it was easy. Since there is a stamped and removable support holding the switch in place I reasoned that the switch would stay put and it does. I took the old panel and siliconed it in place. Once everything is back in place this "modification" disappears behind the bezel.



The switch was no longer giving me headlights but all other lights connected to that switch worked just fine. The connector in the truck was in very good shape so I did not do the heavy duty fix. I bought the switch - Made in the USA - from Auto Zone for under $20. 00.



Bob

 

[Grey Wolf]

Nice tip Bob!

Did you take the old switch apart to determine why it failed?

 

[Bob Beauchaine]

Not yet but I will. From the problems I was having I believe the headlight contact was the only problem area since according to the electrical diagrams it is on a contact all by itself. I will post what I find when I tear it apart.



Bob

 

[Bob Beauchaine]

Well I had a chance to take the headlight switch apart and here is what I found. It was just plain worn out. There were no signs of over heating nor was anything broken. It did it's job for over 173,000 miles and just got tired. It did have di-electric grease in it but that was not part of the problem. The new switch is a Wells SW276 and is working fine.



Bob

 

[Grey Wolf]

Thanks Good to know Bob, maybe that part number should be keep available for the others!

 

[tugboatphil]

Bob,



Thanks for the great tip, AND for making me feel a little more stupid than I thought I was.



I was on a road trip last winter and had headlights, but lost everything else. I was right next to an Advance Auto Parts and it was minutes until they closed. I got a switch for about $10. 00. I could smell the burned part of the old one. The previous owner had all kinds of lights running through it, which I had rerouted.



Anyway, I spent the next hour or so cussing the engineers that didn't leave enough slack to change out the switch without having to lay with my head under the dash. I'm also right at that age when I can't see much of anything that's 2 to 3 feet from my face.



So tomorrow I will look under there to find the plug.



Seriously, Thanks!

 

[Bob Beauchaine]

Automotive Engineer is the best oxymoron I have ever heard - makes military intelligence seem positively brilliant. If they would get off their butts and spend time working with their designs they might do things differently.



Bob