Headlight Switch Melted! WTF? pic included

justinl4322

Well-Known Member
Joined
Apr 3, 2009
Location
raleigh
i have a 97 TJ 4 cyl.i was having some trouble with my headlight switch over the past couple of weeks. the switch was sticking a little and i had to pull it in certain positions to get the headlights to cut on. the switch is a push pull switch for those of you who dont know. the other night around 9 pm as i was attempting to leave work, i cranked the jeep and pulled the switch...no headlights. the driving lights came on but not the headlamps. i opened up the dash to try to see what was going on and saw that the headlamp looked to be burnt. i pulled the whole assembly apart and noticed that the whole headlight switch assembly was melted. what would cause this? also, does anyone have one sitting around they dont need anymore? thanks
ai16.photobucket.com_albums_b14_rockslinginyj_lights.jpg
 
just outta curiosity are you running foglights? are you running them with or without a relay
 
Dodge pickups seemed to have the same problem back during the same year models. Do you run with your gauges dimmed? On the Dodge pickups this would cause the switch to get really hot and do exactly what happened there. Dodge pickups had a recall on the switch...don't know about TJ's...
 
I had a 36 foot deisel pusher bought new in 96 and burnt four headlight switches, I was pulling a 22 foot trailer and just too much resistance. Changed the trailer out to LED lights and problem solved. Might try swapping the bulbs in tail lights to the LED replacements for safety.
 
Might be able to find that switch at the parts house. I got one for an F-series from NAPA
 
Indy Will said:
Dodge pickups seemed to have the same problem back during the same year models. Do you run with your gauges dimmed? On the Dodge pickups this would cause the switch to get really hot and do exactly what happened there. Dodge pickups had a recall on the switch...don't know about TJ's...
Click to expand...

I had to replace my 96 dodge 1500 switch twice, due to the same thing.

I always run with my lights dimmed too. Hmm, guess I know why now.
 
I've replaced several stock TJ light switches and harness ends at work. None had extra lights or anything. The dealer has the wiring pigtail so you can replace that connector, just cut and splice the wires.
 
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