Headlight switch questions

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May 12, 2003 | 10:33 AM

jeff_67cougar

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Junior User

Joined: Aug 2002

Posts: 65

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From: Wabash USA

Headlight switch questions

My 93 Aerostar is going through headlight switches every 6 months or so. When the lights are on the dash lights will go out.
6 months ago the headlights and dash lights quit suddenly. I have replaced the headlight switch twice in the last year or so. First I used an Autozone special. The second was a motorcraft from the dealer.
I remember a recall a while back dealing with overheating headlight switches. The dealer installed a relay. Could this relay be bad now? Does anyone know the p.n. or anything else about the relay?
BTW the headlight switch connector shows that it was very hot at one point. It has brown areas and signs of melting.

Thanks for your help

Jeff

May 12, 2003 | 08:31 PM

eehoepp

Elder User

Joined: Feb 2003

Posts: 586

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From: Tottenham Ontario Canada

Headlight switch questions

My local dealer parts guy recommended replacing the harness connector when replacing the headlight switch. It was under $20 & took about 30 minutes to solder in. When the headlight switch goes, it apparently melts the connector. After 1-1/2 years I haven't had any further headlight troubles. As a bonus, the wire length on the replacement harness lets you extend the harness a few inches which makes it a whole lot easier to reassemble the switch & panel.

Cheers,
Eric