Ford Explorer: Bad headlight switch

I recently had my headlights stop working and traced it to the switch. I
opened up the switch and found that the contacts had heated up enough to
melt the plastic around them which then covered up the contacts. I was able
to cut away the melted plastic and clean up the switch enough to get it
working again. Now this is on a 96 that I have owned for about 3 years. I
always drive with my lights on since I commute over two lane country roads.
This is about 45 minutes each way. It seems that the switch should not heat
up enough to melt the plastic. I was wondering if anyone else has had this
problem.

Dave

Interesting read...

I had the same problem and I started ntoicing the problem a couple of weeks
after replacing the bulbs that were brighter -NOT Stock bulbs

Replaced the switch - dealer did it.