I recently had my headlights stop working and traced it to the switch. I opened up the switch and found that the contacts had heated up enough to melt the plastic around them which then covered up the contacts. I was able to cut away the melted plastic and clean up the switch enough to get it working again. Now this is on a 96 that I have owned for about 3 years. I always drive with my lights on since I commute over two lane country roads. This is about 45 minutes each way. It seems that the switch should not heat up enough to melt the plastic. I was wondering if anyone else has had this problem.
Dave