You can also get some contact cleaner and spray it into the headlight switch
to clean the internal contacts. Auto and Electronics stores sell various
forms of this spray. Good to have around to clean other contacts if you do
electrical work on your van.
Bill
90 Westy Syncro
-----Original Message-----
From: Mark McCulley <transporter99@HOTMAIL.COM>
To: vanagon@GERRY.VANAGON.COM <vanagon@GERRY.VANAGON.COM>
Date: Thursday, February 25, 1999 6:11 AM
Subject: Re: Headlight switch failure (possible solution)

>>I unplugged the switch and somehow it had
>>overheated and melted the plastic on the back of the switch which
>cocked the
>>plug on the switch so it did not make proper contact.
>> I really think the solution to the headlight
>>switch problem (and also a way to get brighter headlights) would be to
>install
>>a headlight relay.  This will take the load off of the switch (which
>obviously
>>can't handle it) and put it on the relay (which is made to take the
>current).
>
>Headlamp switches often overheat as the result of corrosion-induced
>resistance on the switch contacts. Over time enough resistance builds up
>to cause not only a significant voltage drop but also generate enough
>heat to deform the plastic switch housing. This phenomena can also occur
>on a relay--anywhere you have a relatively high current passing through
>a spade lug connection. The best preventative fix is to clean the spade
>lug connections and ensure they provide a good electrical connection.
>
>MM
>
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