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  #1  
Old 05-15-2011, 08:35 PM
Beater Beater is offline
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Default Yep, melting headlight switch q again

Any real fix for this? I harvested a harness from the truck I got my tacho-dash, and it had 165k on it and the harness was fine. Mine burned up at 100k. Will cut-n-splicing the headlight wire harness do the trick? Why would not it melt also?
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Old 05-15-2011, 08:37 PM
pooleo pooleo is offline
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Default Re: Yep, melting headlight switch q again

you got anything extra running off your headlights?
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  #3  
Old 05-15-2011, 11:21 PM
Gumcrew2 Gumcrew2 is offline
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Default Re: Yep, melting headlight switch q again

My factory headlight switch is friggin crap
Burnt all to hell, and when you turn it to make the dash ligts brighter/dimmer turn on the dome light it'll SPARK.

Junkyard
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  #4  
Old 05-16-2011, 10:28 AM
Beater Beater is offline
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Default Re: Yep, melting headlight switch q again

Quote:
Originally Posted by pooleo View Post
you got anything extra running off your headlights?
All stock, even the headlight bulbs. No fogs or anything else.
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Old 05-16-2011, 10:58 AM
pooleo pooleo is offline
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Default Re: Yep, melting headlight switch q again

if you are stock then you have a short somewhere melting your switch. I had ran my plow lights off the headlight wiring and my switch got really hot. Try taking your bulbs out turn on your switch and see if it gets hot, maybe this will help you track down whats going on
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Quote:
A Gladiator does not fear death. He embraces it. Caresses it. Fucks it. Each time he enters the arena, he slips his c0ck in the mouth of the beast, and prays to thrust home before the jaws snap shut. - Oenomaus
Ball Joints/Upper A-Arms How To
Replace Door pin/bushing
Repair broken dome light tabs
VIDEO OHC Install
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  #6  
Old 05-16-2011, 02:13 PM
drppdyllwrngr drppdyllwrngr is offline
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Default Re: Yep, melting headlight switch q again

here is what i did with mine....

Quote:
Originally Posted by drppdyllwrngr View Post
the headlight switch pigtail is trashed. have two wires that are burnt badly. got a new pigtail from carquest. heavy gauge wires all the way across it. part # ECC 57-4783. I highly recommend anyone that runs higher wattage headlight bulbs to upgrade this wiring. i have higher wattage bulbs, plus the projectors and my headlight switch gets extremely hot. also bought the upgraded headlight harness from LMC truck. it's plug and play, but pulls the power off the battery instead of through the headlight switch.


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Old 05-17-2011, 06:21 PM
FireRanger FireRanger is offline
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Default Re: Yep, melting headlight switch q again

If you are attaching additional lights or higher wattage lamps to the factor headlight circuit, you as asking to melted harnesses or a fire. The factory wiring is designed to handle the factory wattage, nothing more. You can use your factory high or low beam circuits to drive relays to control additional lights.

The headlight switch or harness melting without additional lights or high wattage bulbs is usually a result of an isolated bad connection. High resistance causes heat. That heat will be where the bad connection is located. So if the switch/plug is melting, the problem is either IN the switch or in the plug.
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  #8  
Old 05-17-2011, 07:03 PM
4evermodding 4evermodding is offline
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Default Re: Yep, melting headlight switch q again

hat year is your truck? i have dozen's of ranger harnesses. and if you need one, i will send it.
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  #9  
Old 05-18-2011, 01:06 PM
TerrenceStuart TerrenceStuart is offline
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Default Re: Yep, melting headlight switch q again

BRU come's thru!
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  #10  
Old 05-18-2011, 06:33 PM
Beater Beater is offline
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Default Re: Yep, melting headlight switch q again

I appreciate it 4ever, I cut a harness from a newer year, don't know what year, but it has the pink plug like in the pic, my truck has the black plug. Does it mean anything? Also it is the plug area and some wires that get hot, the plug melted a long time ago. I got a new switch and had to kinda re-pin it, kinda not. It has worked fine since but still gets chinga hot. I don't drive the truck at night much so it has not been a big deal. But I never put my dash piece back on and the switch hangs in the breeze, I think it will melt for certain if I stuff it back in the dash. So just splicing on a new plug will help? A new switch did not cool it down. Thanks fellers.
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  #11  
Old 05-18-2011, 06:36 PM
FireRanger FireRanger is offline
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Default Re: Yep, melting headlight switch q again

It's probably your "kinda repinning" job creating high resistance and heat.
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  #12  
Old 05-18-2011, 10:33 PM
Beater Beater is offline
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Default Re: Yep, melting headlight switch q again

Negative, the switch is as hot as it was before. The plug melted and I trimmed off the melted part and attached the wires directly to the switch, just went around the plug.Those same two wires that seem to be the problem. If anything it has improved because the lights have not suddenly quit at 70mph in the middle of nowhere like the last time. Does anyone have any real suggestions on why this thing melts wire harnesses in the first place? I understand the mechanics of why, I don't know why Ford would make it this way. I can't see what that custom wire harness is about or maybe I could do that. Seems like this would be simpler given my truck is 13 yrs old.
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  #13  
Old 05-18-2011, 10:38 PM
pooleo pooleo is offline
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Default Re: Yep, melting headlight switch q again

the plug should not have any heat to it. have you tried unplugging your bulbs and see if the switch gets warm/hot?
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1999 | Ext. Cab | 4.0 | 4x4 | 4.10's
Quote:
A Gladiator does not fear death. He embraces it. Caresses it. Fucks it. Each time he enters the arena, he slips his c0ck in the mouth of the beast, and prays to thrust home before the jaws snap shut. - Oenomaus
Ball Joints/Upper A-Arms How To
Replace Door pin/bushing
Repair broken dome light tabs
VIDEO OHC Install
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  #14  
Old 05-19-2011, 04:05 AM
drppdyllwrngr drppdyllwrngr is offline
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Default Re: Yep, melting headlight switch q again

the harness that lmc sells (the one i pictured before) is a relay harness that plugs into your headlights and pulls power directly from the battery. it uses the factory headlight switch just as a switch for the relay = less current going through it (no heat). mine used to get so hot i thought the plastic panel was going to melt. but i was had upgraded bulbs, plus another set in the projectors. after the harness and new pigtail, the headlight switch stays cold to the touch.
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  #15  
Old 05-19-2011, 04:17 AM
FireRanger FireRanger is offline
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Default Re: Yep, melting headlight switch q again

Ford didn't design it that way and this isn't a common recurring problem at all. It is doing this because something is wrong. The fix is you have to find where the high resistance bad connection is located. That problem is usually in or at the switch itself.

This is assuming you aren't using aftermarket high wattage bulbs.
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How to: Aux light wiring, relays, & fuses
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Info: HID Projectors
How To: NO HEAT Troubleshooting Guide
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