Burning up headlight switches

[JSPulliam21]

I have been posting on other forums, and getting nowhere. So here goes. I have been having trouble with my dash lights and parking lights for some time. It all started with the dash lights flickering and going out. Then they would come back on and go off randomly, and go out for good. I thought the problem was the headlight switch, so I replaced it. The new switch was OK for a while, but it eventually did the same thing. Now, I can see that there is a problem with the truck. I replaced all of the connectors going into the headlight switch, traced the harness going to the switch until it disappeared into the main harness, replaced the switch again, and I still can't find the issue. Recently I discovered a new problem. The 15 amp fuse for the parking lights was loose in the socket. I tweaked the legs on the fuse so it would make good contact, and it was OK. I checked the power wires for continuity to ground, and have not found any shorted. All ground wires are grounded as well. I can blow the fuse for park lamps if the switch is installed and I wiggle the knob around. Sometimes there is a spark and the fuse blows. If the switch is just hanging out of the opening I cannot get the fuse to blow. I know this was a long post, but I am at my wits end. Just give me what ya got!

 

[JSPulliam21]

I did find that when I wiggle the park lamp fuse on the side of the dash that the lights flicker, and I can get them to go out. Now, how do I get to the back of the fuse block to investigate further?

 

[scott2001]

i dont know that put genos garage make a heavy duty head light switch it takes all the pull off the switch and make a new relay staight to the battery it might help

 

[Billysgoat]

I'm going to guess a broken wire just aft the switch. If you are only able to blow the fuse with the switch installed that means the problem is right there behind the switch.

Try this, first, pull the switch out and look really hard and thoroughly at all wiring and connectors, try to find any where that the wiring gets kinked or bent sharply once the switch is installed in the dash. Look for any signs of chafing on the wiring there in the dash. Once all this is done and if you have not found any obvious problems it's time for step two.

Make sure all the wiring is free enough so that you can wiggle individual wires. With the switch out of the dash, start wiggling individual wires and see if you can get a fuse to pop. If you can pop a fuse doing this, start tracing that wire out and find the bad spot or run a new wire to replace it.

Hope this helps.

 

[JSPulliam21]

Billy, I did all of that, and could not duplicate the lighting problem. However, when I wiggle the fuse in the socket I can get the lights to flicker. Clearly, there is a bad connection in the fuse socket. How do I get to the back of the fuse block?