Headlight switches are internally protected with an auto-resetting circuit breaker on the headlamp circuit. This is the ONLY circuit that does NOT have a separate fuse in the block. If you have increased the headlamp wattage higher than that of the OEM headlamps, you are going to have additional heat and potentially shorten the life of the internal breaker. Otherwise, as long as the connections at each terminal between the harness connector and the switch itself are snug, you should be fine. The harness connector is the most likely culprit if heat is still an issue after replacing the switch.

As to the mis-alignment of contacts for the individual lighting circuits, the only issue it can be is the switch. It is the component that controls what makes contact and in what position. The rest is just wiring and light bulbs.