Does anyone have experience with the headlight switch? (97 Avant 2.8 last of the C4 bodies!) Or a sugestion as to how to stop it from breaking?

I'm going to replace the switch for the third time in 3 months. I'm getting pretty quick at pulling the air bag and steering wheel but I'm getting tired of doing it over and over again. I might be wearing out the screws!

In Dec the first switch failed and I put a used one in. A few weeks later it failed so I put another used one in - (covered under a guarantee) thinking that it happens sometimes. Now the third one has failed in the same way - the headlight contacts. I took the first two that failed apart, found the offending contact, and was able to put something together that worked. It looks as if there is a bit too much heat, a little plastic piece is melting/softening and stopping the contacts from making good contact.

I'd like to think it is just a fluke but don't know for sure. The contacts power the fog lights and the low beams thru the lamp control module.

Maybe I'll just use a toggle switch! LOL

 

You could have a short circuit or oxydized contacts, which cause the excess heat to melt the plastic. I have never had any problems yet with the headlight switch. I did take the speed control switch apart on a 1998 Audi A6 wagon and the circuit board was badly tarnished. I used steel wool to remove the tarnish and then a thin coat of silicon dielectric grease to prevent it from oxidizing again.

 

Since I put two switches together for this try, I cleaned the contacts and used dielectric grease.

I haven't had time to look at the last switch so I don't know why it failed. Until I figure it out I'll leave the fog lights off to keep the current low.