Melting Main lights switch fuse

[Ranger Sport Honduras]

Sup guys,

I have the following issue; a few months ago my truck went light less. I checked and the main lights swtich fuse was melted, iIreplaced it and got lights for a while until it melted again. so I checked and replaced the multi function swtich and no luck.
Then i checked and replaced the main lights switch, i took it apart and the copper inside was burnt.


So I thought the issue was fixed, until last night. Bam, no lights. I check the fuse and it is melted again. the slot even looks burnt.

I haven't done anything to the stock wiring and headlights except for a pair of fake/cheap Xenon bulbs when I got it, back in 08. There is nothing else done to it besides that.

What could be causing this problem?


Thanks in advance, RSH

 

[4x4junkie]

Sounds like you might have an intermittent short circuit (those can be the greatest effing PITA to fix too).

My best advice is stick a new fuse in there and turn on the lights. If they come on, start jiggling the wiring harnesses until you can find where the short is. If the fuse blows again right away, then the short is active. Time to get out an ohm meter/continuity tester.

 

[dangerranger83]

It could be just that, the cheap bulbs.

Sent from my SPH-D710 using Tapatalk 2

 

[Ranger Sport Honduras]

Whe i put a new fuse the lights work fine for around 3 to 4 months, its just that the fuse starts heating up and melts with the use of lights.


I will look for the normal bulbs and put them back, maybe that helps.

 

[Sasquatch_Ryda]

So the plug at the headlamp switch was melted? Was it replaced? Could be a bad connection there causing high resistance if it is all melted and burnt.

 

[4x4junkie]

Whe i put a new fuse the lights work fine for around 3 to 4 months, its just that the fuse starts heating up and melts with the use of lights.


I will look for the normal bulbs and put them back, maybe that helps.

Are the connections where the fuse goes in discolored from heat? If so, then maybe that's your issue (same goes for at the headlamp switch like Sasquatch mentioned).

If the bulbs are more than 75/85W or so, then yea they certainly are not helping either (stock 9007s are 55W/65W IIRC)

 

[Ranger Sport Honduras]

The head light connectors arent burnt, but i will clean them right now, the fuse box is burnt. i will check the Wats on the bulbs and look for the stockers.

i will post more in a while