My Expy has 150k miles and I keep blowing random COP's. At the rate if about one a month. Any ideas???

The second issue is the passenger headlight low beam fuse get really hot when it's on the low setting so the truck needs to always be driven with the high beams on. I've tried it with different bulbs with no luck.

Any help guys?

 

Heat is a sign of resistance at a connection point. Perhaps the terminals the fuse plugs into need a bit of cleaning or tightening.

 

I'm not sue about your COP problem, but your headlight issue is cause by resistance somewhere in the circuit. Hook up a multimeter and see if the resistance is within spec. Also there is the possibility that it has the wrong size fuse in it, but I doubt it. Look in a service manual or online to find the specs for the resistance in the headlight circuit. Also check the high beam resistance, I am not sure how similar they are but it might be a good reference point.