Headlight Switch Issues - Ford Powerstroke Diesel Forum
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Old 11-19-2012, 01:21 PM
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Headlight Switch Issues

I've been all through my headlight system, changing the multifunction switch, the headlight switch, and the connector. In the past few months, I've had an issue with the headlights shutting off. When this occurs, the dash above the headlight switch becomes hot, and the headlights simply go out. This occurs whenever the heat is on, dash or floor, and it occurs faster when using the high beams. The only way I've found to prevent it is to run the blower on the 'cool' setting through the dash vents. This is less than ideal when it's 25 degrees outside, so I'd like to know if there are any other ways to prevent this problem from occuring. I'm not sure if I have a defective switch or what might be going on other than that. Any other insight?
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Old 11-19-2012, 01:44 PM
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the switches are known to fail because all the juice for the headlights runs through them. while i have not had the problem you are describing i have had problems with my headlight switch. upon pulling it apart i noticed that it had gotten hot and the plastic block with the wires running into it had bubbled and pulled a wire off a connection causing me to have no dash lights/park lights. i would think something similar is happening to you. i got a new switch and plastic and it helped for a while but then the same thing happened again so i got a relay/harness from someone i forget who and it plugs into the headlights and connects to the battery and now all the juice to power the headlights go through the relays and not the switch

here is a pic of the block

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Old 11-19-2012, 01:52 PM
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yes sounds like your switch is melting... you will need to replace what is damaged, and then install a headlight relay harness. u may see your headlights get a little brighter too!

i need to install this also, i smelled a little somethin somethin the other day, i believe i was coming from the headlight switch
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Old 11-20-2012, 08:44 AM
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Any ideas as to where I might acquire this relay? I don't mind to get a relay and wire, I'm just not sure how to do it. If there's a pre-made harness that's reasonably priced I would just as soon do that as I would wire one up.
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Old 11-20-2012, 09:48 AM
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dfuser makes one, painless i believe makes one, lmc truck has one though they use funky relays, i can't remember where i got mine, but will check when i get to the shop. it was about 70 shipped and was the nicest/highest quality one i could find
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Old 11-20-2012, 09:51 AM
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They do make a prewired kit that is basically plug and play, having troubble finding it. I know painless wiring makes a kit, and so do a few others. I will keep looking
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Old 11-20-2012, 01:40 PM
the baconator
 

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crap i forgot to get the name of the harness or any pics
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Old 11-21-2012, 06:28 AM
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Painless Performance: 9004 & 9007 Headlight Bulb Conversion Harness

There's one from Painless that runs $240 bucks...
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Old 11-21-2012, 08:00 AM
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If you have a little electrical know how you can do the relay upgrade for about $30 using painless relays and bases. I've done it on 4 different vehicles in the last couple of months and it makes a big difference.
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Old 11-21-2012, 08:28 AM
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Go HIDs and they come with the relay harness
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