I went down south for several days to do some roofing. I took my around
town hauler since I needed to carry 16 sheets of plywood as well as a
bunch of other materials and tools. Since I really only use that van for
local hauling I haven't bothered to do much to it other than keep
everything mostly working. In 4 years I have never had it more than a
hour or two from home until recently. I started down late and ended up
driving about 3 hours during darkness. Most of that was with the
high-beams on since it was a somewhat desolate route. No problems,
everything fine, until the next evening when I needed to go get some
beer for a dinner/BBQ I was invited to. Started her up, NO HEADLIGHTS.

Usual story, holding up the dimmer lever made the brights come on,
letting go, no headlights. I tried the wipers, no go, unless I held up
the dimmer lever, then the wipers worked too. Ok, bad X contact in
ignition switch, easy work-around.

I looked in the glovebox and with some sense of relief pulled a spare
switch out, took the lower cover off the steering column, and tried to
pull the wiring connector off the old switch. It was good and stuck, so
I disconnected the battery ground side so I could safely pry it off with
a screwdriver. Came off, along with some melted plastic from the old
switch that had been gluing it all together. I pushed the wiring
connector onto the loose spare switch and connected the battery. I used
a flat blade screwdriver to turn the bare switch, engine started and
lights worked fine. Good enough to run errands and get me home. Today I
properly installed the switch and added headlight relays so it will
never happen again. Should have done that all along. At least I had the
spare switch when push came to shove.

Mark