As David and others know I have been repairing headlight switches for 7 + years as long as they are not missing parts. If you don't add a switch saver to your original switch or to a repaired switch then count yourself lucky. They will melt on the inside depending on how long the lights stay on and how many times you use them. So if you like the original switch operation and you don't add a saver kit for $19.95 then you just lucky for now, but it will happen. John Hervey www.specialtauto.com www.deloreanautoparts.com -----Original Message----- From: dmcnews@xxxxxxxxxxxxxxx [mailto:dmcnews@xxxxxxxxxxxxxxx] On Behalf Of David Teitelbaum Sent: Friday, May 29, 2009 8:32 AM To: dmcnews@xxxxxxxxxxxxxxx Subject: [DML] Re: Headlight switch repairs The design is probably considered a "success" since it lasted over 25 years! The problem is not only the design (and construction) of the switch but the circuit itself. The switch carries the direct current of the side markers and they are fused AFTER the switch so if there is a short circuit in the marker lights the switch has to carry that whole load BEFORE the fuse will blow. Not the best way to do it. Using relays will reduce the current through the switch reducing the heat and helping the switch last a lot longer. Changing over to L.E.D.'s for the marker lights will also help a lot. Going with halogen type lights will increase the load so if you go that way you really should consider relays for the switch to control. You also should check from time-to-time the marker light sockets. They are prone to corrode and when they do they can cause a high current through the headlight switch. David Teitelbaum vin 10757 --- In dmcnews@xxxxxxxxxxxxxxx, "dadoc2791" <gekko@...> wrote: > > Dave, > > No question that the overall design is poor in regard to the amperage carried by the switch in the original schematic, but I have about 35k miles on my car and this is the first time (to my knowledge) it (the switch) has required repair, so I figure I've been p ------------------------------------ To address comments privately to the moderating team, please address: moderators@xxxxxxxxxxx For more info on the list, tech articles, cars for sale see www.dmcnews.com To search the archives or view files, log in at http://groups.yahoo.com/group/dmcnewsYahoo! Groups Links ------------------------------------ To address comments privately to the moderating team, please address: moderators@xxxxxxxxxxx For more info on the list, tech articles, cars for sale see www.dmcnews.com To search the archives or view files, log in at http://groups.yahoo.com/group/dmcnewsYahoo! Groups Links <*> To visit your group on the web, go to: http://groups.yahoo.com/group/dmcnews/ <*> Your email settings: Individual Email | Traditional <*> To change settings online go to: http://groups.yahoo.com/group/dmcnews/join (Yahoo! ID required) <*> To change settings via email: mailto:dmcnews-digest@xxxxxxxxxxxxxxx mailto:dmcnews-fullfeatured@xxxxxxxxxxxxxxx <*> To unsubscribe from this group, send an email to: dmcnews-unsubscribe@xxxxxxxxxxxxxxx <*> Your use of Yahoo! Groups is subject to: http://docs.yahoo.com/info/terms/