Headlight switch keeps getting ruined.

[Big SW]

Well, I got a problem. My 1986 Chevy K10 keeps ruining the headlight part of the headlight switch. I replaced the headlight switch a while ago because the courtesy lights were not working. Later on, the headlights quit. I found out that power wasn't getting through the switch. I replaced it and its now happening again. Everything else works fine except the headlights. the dimmers switch tested good. Any ideas?? thanks!!!!

 

[Camar068]

sounds like you've got a bad ground somewhere, or a bad positive wire leading to the switch. I'd start with the grounds. I'm sure you'll get better input shortly of where exactly to look.

If it's not ground it's gonna be a visual on each wire leading to/from the switch.

 

[HotWheelsBurban]

Yup if something keeps getting fried, there's a short somewhere. Pinched wire under the dash or in steering column? Or underhood?

 

[Radiohead]

Check connector quality too. This is why I'm on the third blower motor switch in my impala

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[BadHabit]

as Radiohead points out, high resistance at a plug terminal will create heat and cause subsequent heat damage to switch internals...

My first thought was headlight bulbs have been replaced w/ higher output, higher current devices...this may increase current draw in excess of the rated current of the switch design.
This can be rectified by installing a remote relay, so the switch only needs to supply a small amount of current to actuate the relay...the relay carries the actual headlight current.
The relay which is typically located somewhere near the headlights...inner fender, radiator support, etc...
Headlights will see full system voltage and burn brighter too!