I had an electrical service company repair a short circuit in the parking lights 2 years ago and they said at that time that I should replace the head light switch, but they didn't have one in stock. They solved the short circuit and ordered a new switch for me.
When this problem came up, I went to install the switch, and I noticed that a couple of the wires near the switch looked like they had overheated as there was a few areas where the insulation had melted a bit. I cut out these damaged bits and joined on some new pieces of wire. I replaced the switch, but it made no difference.
This switch is a direct replacement for the old switch. It is a rocker type switch that has 6 terminals on the rear. There are 3 terminals on the left and 3 terminals on the right. I did a thorough test with my ohmmeter and there was no connection between any of the terminals on the left side and the terminals on the right side. It was just like there were two switches in one. If a hot wire is hooked up to the center terminal on the left set of terminals, and the switch is rocked down, then there is a connection with the upper terminal on the left side. If the rocker switch is rocked up to the top, then there is a connection to the lower terminal on the left side. There is no connection to any of the terminals on the right side. The same connections are on the right side, but there are no connections between the left and right sides.
There is only one hot power wire connected to the center terminal on the left side, and nothing to the center terminal on the right side. when the switch is pushed down for the parking lights, there are wires secured to both of the upper terminals with a jumper wire connecting them and then another jumper going to the variable switch for the dash lights. I don't know why they used both of the upper terminal since there is no power on the right side. They could have just bundled them together onto the left terminal.
All the parking lights work in this situation. When the switch is rocked up for the headlights, there are no headlights turned on and the parking lights are also off. Although the light do not light up, there is 12 volts showing at the lower left terminal (as there should be).
Again, there are wires connected to both of the lower terminals. Another puzzle here is that there is a low voltage of 8 volts showing on the lower right terminal and its wire even though there is no power supplied to it's center terminal, there must be some feedback from somewhere.
All these wires look to be too light to be powering the headlights directly. I don't know if the wires were messed up when they repaired the short in the parking lights, but something just does not seem to be right. When we are camping, we usually stop for the day by 3 o'clock, so I don't think that we ever drove when the headlights were required. But a couple of weeks ago, I did drive much later and I then found out that the lights didn't work when I needed them. I guess I will have to try and trace the wires from the switch and/or the headlights to try and find the problems.
Thanks for your help.