It seems that everyone who has a vanagon eventually encounters the failed
headlight and/or failed ignition switch problem.  Too much electricity for
the marginal when new components.

Because this is your second headlight switch failure in a very short period
of time you need to explore all of your wiring connections.

My windshield had been leaking in the area directly over the ground point
and had even dripped onto the back of the fuse box. I ran an ugly bead of
silicone around the outside edge of the windshield gasket, removed and
cleaned the two multi-point ground connections, and cleaned up the
connections on the back of the fuse block.

I have not had any problems since, however; when my headlights are on, I put
my thumb on the headlight switch to see if it gets hot (BAD).  With just the
low beams on it does not get warm.  When the high beams are on the switch
starts to get warm after about an hour.

The headlight relay bypass stuff that I bought at radio shack is definitely
going to get installed soon.

Randy Herd
86 GL Weekender
68 Kombi
98 Jeep Cherokee

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