Fixing The Keykeeper's Pickup Truck Headlight Switch

The Keykeeper's truck had another breakdown! This time around, the headlight switch stopped working correctly. It would frequently introduce a delay before the headlights would turn on, and arcing sounds could be heard coming from the switch. It was just another case of some slightly underrated contacts developing burned spots over time that would prevent the flow of enough electricity for things to work properly and reliably.

Most later GM vehicles switch only a signal line with the in-dash headlight switch. A relay does the actual high current switching.

Category:

Autos & Vehicles

Tags:

• truck
• 1994
• Chevrolet
• C1500
• W/T
• headlight
• switch
• repair
• fix
• keykeeper
• uxwbill

[luke4090]

Ever work the sewing machine into the project? lol

[uxwbill]

@luke4090 Nah...maybe we should have!

[maplewoodsp]

Cool... What did you use for anti-oxidant? I like Caig products.

[uxwbill]

@maplewoodsp I don't remember now. The switch did eventually have to be replaced due to plastic failure.

[HDXFH]

i've never heard of noryl must be a very common plastic then

[uxwbill]

It's said to be a combination of polyphenylene oxide and polystyrene, which would certainly explain its texture and fragility.

Interestingly--assuming the WP article is correct--it's also an unusual combination for a plastic formulation since most polymers are incompatible with each other.

[me748]

same story with my 90 silverado. switch got pushed through the dash shroud. mine were delayed and finally stopped working all together. when i was fixing up the inside of mine, i took the shroud off and took the switch and dimmer wheel switch apart cleaned and sanded the copper on the headlight switch and jb welded the switch assembly back to the dash shroud. works great now.

[uxwbill]

That's how nearly every older vehicle did it--by running the power through the switch in the dash. Only later did the use of relays start to show up.

I'm surprised that they didn't protect the lighting circuits separately so that if one light had a problem the other would stay on. My guess is that it's a cost thing--that much more wire and another switch contact wouldn't be cheap over a production run. Or maybe they just never thought of it.

[ArcaneLion]

Nice Video!

You made some good comments about that switch. I had the same problem with my Opel Omega Caravan. It's great fun loosing the lights in the middle of the night while driving 160 Mph on the german motor-way.

Its a real deathtrap...

I have no idea what or IF they were thinking when they dicided to run all the power through the switch.

[howdy0473]

im sure you all are very busy. just want to tell you guys i really enjoy and look foward to seeing what yall are up to. have a great weekend. :-)