Pete Miller

My headlight switch and connector are fried. I have ordered a new switch. I would buy a new connector and harness if I new where/how that harness terminates at the end opposite of the switch connector. The NAPA switch connector picture shows the connector harness ending in a bunch of bare wire ends. I have a service manual but am weak at reading diagrams. Can anyone describe the wiring harness replacement for me? Thanks.

xtoyz17

I'd say go to a junkyard and cut off 6 inches of wire plus the plug, cut off what you have that melted, and just match the wires. Don't have to be a genius to do that, just gotta be careful and willing to take a little bit of time.

NoSeeUm

Maybe take some pictures, that you can refer to later, before your start disassembly on your truck.

Jim

smokeyram

I had this happen as well. 2 options, 1. get the new plug harness. the other is to cut the wires back, one at a time, crimp on spade connectors and hook them right to the new switch terminals. As long as you hook them up everything will work fine.

TIMMY22

X2 what smokeyram said.

I wish I could get to the bottom of why this happens.

Mine did it, everything still works fine.

xtoyz17

It happens because the switch and wiring weren't design as well as they should have been. Too much load, too small of wiring, etc... and things start to get toasty pretty quick. Start to add fog lights, running lights, marker lights, any other accessories on that circuit and it's just asking for trouble. Doesn't matter if it's OEM or aftermarket.

dozer12216

You got it xtoyz17 . Standard HL sw works great up to a point. Needum relays when go extra stuff.

oldblues

hi
the problem is the factory wire harness is to light to handel the current !

cure the problem by getting the upgrade harness and you can safely use 80/100 headlight bulbs , i love mine !

justme-

Depending on you're truck- there was a recall on some for that problem......

MikeBC

yep, my 99 had that recall in late 2000