I have a 95 SLE. The head lamp switch keeps burning out causing my IP lights and even my taillights to go out. I can replace the switch (have 4 times) but this is getting expensive. The connector is melted. I bought a new black connector piece and want to have all 14 (!!) wires reset into the new connector.

Does anyone have any knowledge of a factory problem? Does anyone have any suggestions, warnings, etc. I know little about electrical systems. I have a friend who can change the connector, but I'd like to check if there is excess resistance somewhere. I'd like to know if anyone else has had a similar problem and knows how to fix it.

You have a short somewhere, probably in the headlight circuit (higher current there).

I don't have a schematic for the 95, so I can't be of much help other than that amazing advice. Someone will step up shortly with some better info.

cough *ack* cough JR...cough cough

He has a 95

Need to know if there is a TSB - Possibly someone saved them from DeathRat'* old site?

DeathRat has and still can provide TSB'* if asked...PM maybe?

I want to re-post this message. I still have this problem. I have found that I can clean off the terminals on the switch and put it back on the car. It will work normally for a while before going bad again. I have two that I switch back and forth. I did re-do all the end pieces of the wires in the head lamp harness years ago, to no avail. Interestingly, if I strictly use Twilight Sentinel, I have dash and tail lights as usual. But, if I turn off TS and pull the switch the old-fashioned way, my dash and tail lights don't come on -- only the head lights. I have the shop manuals and therefore the schematics of the switch wiring. But, it still doesn't make sense where the extra power is coming from. Has anyone else seen a problem like this? I'm sure there is a short somewhere but where do I look? It may or may not be related, but the temp controls background lights have flickered out too. The schematics make it seem like there is no relationship.

Thanks

I will get PM'* out to our gearheads to see if we can't get you a response. I am not aware of this as a general issue with out cars, but we will beat the bushes and see what we can come up with.

From an general perspective, many component failures resulting from excess amperage can be a direct result of loose connections. In manufacturing plants, for example, we use infrared cameras to scan electrical boxes to detect hot spots. When we find a hot spot, the fix is usually tightening loose electrical connections. Do you have any wires that were spliced in for repairs, or added for aftermarket equipment, where the connections are not soldered? Check the integrity of each wire connection in the hard shell connector that connects to the headlamp switch. Check to see if any of the pins in the switch are loose. Track the wires back and look for loose connections.

Just some random thoughts on things to look for while we see if anyone in the forum can shed some light on your problem.

I have had to replace that switch 3 times in my '95 (in 10 years). And i would have had to do it again, except i learned to like the twilight setting. My problem is an upstream load which cooks the switch. Besides the switch, I remember replacing the wires. It took a while after the wires, but it did it again. I have a box with old switches, if one of them is still in there, I'll let you know which wire is causing my problem and see if i can follow it in the FSM..

There was a known issue with the 95 switch. GM updated and changed the switch for the 96 year. Most find that changing the burnt harness and updating the switch fix the issue.

The recall per Alldata is 94V190000: Lighting Control Module Defect. It is for cars with the twlight sentinel.
It appears there is an internal issue" control modules which may experience excessive current leakage due to damaged surface mounting capacitors. This condition could result in a loss of head lamps and park lamps."
You may be able to call a Pontiac dealer and see if they can run a VIN report to see if the recal was ever done.