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The light switch on my Aerostar is finally going to require replacement. We have lost dash lights completely now - used to be able to get them back by wiggling the ****. They come on in the parking light position, but go off when I pull the switch out to the headlight position, and no amount of fiddling will get them on. I picked up a switch at the local Ford dealer. What kind of job am I looking at to put it in?
It's not too hard, just be sure to disconnect the negative battery cable to avoid the possibility of blowing any fuse(s). Then remove the retaining screws and lift off the cluster finish panel, remove the left pod assembly retaining screws, disconnect the wire connector at the rear of the switch, and finally, remove the two headlamp switch retaining screws and remove switch. (from Chilton's Manual)
Take care when removing the finish panels, don't force them too hard as they may split/break.
If memory serves me right, I seem to remember some posts on this forum indicating that the plug at the back of the headlight switch has a tendancy to melt. Do a search for "headlight switch" and see what additional information you can find. Use the quotation marks in your search or you'll get all the additional threads that include lights anywhere in the thread.