2nd Gen Non-Engine/Transmission Headlights / tail lights

[fest3er]

You don't have *just* taillights? I suspect you have *no* running lights, front or rear.

It took 25-odd years for my '98 switch to finally fail, due to a manufacturing defect. The spade on the switch that connects to the running lights was a little burnt, indicating heat/resistance/corrosion between the spade and the internal post/stud. Fiddling with it, I noticed the riveted connection was loose. This is likely why others have reported melted connectors over the years. I soldered it as best I could; it worked for some days. When it failed again, I ordered a replacement from Rock Auto and installed it. I've had no problems since.

If the spade looks like it got hot, likely the lug in the connector also got hot and corroded a bit. Be sure you clean it up; maybe use an Xacto blade to scrape it

 

[SAndreasen]

It’s a brand new switch and a brand new connector . All the lights work just cannot get headlights tail lights are running lights at the same time. Went to pull the switch on one night and They quit working . Last night, I pulled the switch again and they started Working

 

[K7NUT]

That is frustrating, I know. A few months ago, intermittently, my lights, all of them would go out!?
At first I didn't suspect the headlight switch, I had replaced it and the plug a few years back, but when nothing else made sence, I pulled it out. Much to my surprise, it was darkened where the(I want to say green wire)which feeds the headlights, so I grabbed my OHM meter to check exactly how many AMPS are passing through that switch? I tapped into my H beam wire to fire two 30A relays for my 100W lights, so I was suspecting that was the draw or overdraw. Much to my surprise with the H beams ON, I was only pulling just over 9AMPS. That doesn't seem to much, but I decided to put a relay in for that headlight circuit to let it do the heavy lifting and hope that saves my headlight switch. So now, the HL switch just fires the relay and all HL power comes thru the 30A relay. It may be over kill, but we shall see how it goes?