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Re: ford ranger headlight switch getting hot-instr....
If the connector heats up its building a resistence up if its hot there then that is the problem the connection as if the problem was elsewhere it would heat up there first and a direct short would imediatley melt the wires yates210456
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12V power passes through 15A fuse 33 (the one that keeps blowing?) in the battery junction box and on to the main light switch. When the main light switch is set to PARK, 12 volts is routed via the BRN lead to the park filaments of the dual park/turn lamps. These lights remain on when the headlight switch is turned to HEAD.
The main light switch gets its 12V input from 7.5A fuse 11 in the central junction box and the same 15A fuse (33) identified above. When the main light switch is set to PARK, 12 volts is routed via the BRN lead to the instrument panel dimming module and module output is applied to the panel illuminating lamps.These lights remain on when the headlight switch is turned to HEAD.
The input to fuse 33 is hot all the time so should read 12V. If you read 12V at the TAN/WHT connection with the fuse out, something is definitely not right. I'm sure you have noted that the fuse is common to the non-functioning circuits you mentioned.
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It is pretty common for this problem to be a bad headlight switch. I would advise testing the switch before replacing it. That being said I would give it a 90% plus chance of being a bad headlight switch. If you want to test it yourself I would recommend getting a good repair manual at a major auto parts store. This will have a wiring diagram in it and will allow you to test the switch ones it is removed.
I believe headlights have a self resetting circuit breaker. Perhaps the headlight switch is bad, or the dimmer switch... both must work for headlights to work. Get a meter or test light and check to see where you're not getting power. I hope this helps.
Remove the ash tray assembly and the finish panel (snaps off).
On the Explorer, remove the rear window wiper and heated backlite switch assembly (snaps out).
On the Ranger, remove the storage bin (snaps out).
Pull the headlight switch knob to the headlight on position. Depress the shaft release button and remove the knob and shaft assembly.
Fig. 1: View of the 1991-94 model headlight switch control knob release button
On 1995-99 models, remove the instrument panel finish panel.
Unscrew the mounting nut and remove the switch from the instrument panel, then remove the wiring connector from the switch.
Fig. 2: Exploded view of the 1995-99 model headlight switch componentsTo install:
Connect the wiring connector to the headlamp switch, position the switch in the instrument panel and install the mounting nut.
On 1995-99 models, install the instrument panel finish panel.
On 1991-94 models, perform the following:
Install the headlamp switch knob and shaft assembly by pushing the shaft into the switch until it locks into position.
On the Explorer, install the rear window wiper and heated backlite switch assembly.
On the Ranger, install the storage bin.
Install the finish panel and the ash tray assembly.
Connect the battery ground cable, and check the operation of the headlight switch.