Dodge: headlight switch, crank sensor, customers cars

Question
Hi Tim,
 I had a headlight switch that started to malfunction.  The other day the headlights would go out until I jiggled the switch.  You could smell the burned connection.  I replaced the switch with a new one.  You could see where the switch plugs in a little bit of melting in one of the terminals.  The new switch seemed to work fine.  Now the switch pull is hot and you can smell a little bit of a melting plastic smell.  After putting in the new switch, everything seemed more brighter.  I think too much power is going through the switch making it hot.  The fuses are fine.  What do you think it might be and what are some possible solutions?  I appreciate your help,   Mike

Answer
HEY MIKE,DID YOU USE A OE SWITCH(ORIGINAL EQUIPMENT)OR A PARTS STORE SPECIAL? SOMETIMES THE AFTERMARKET STUFF IS JUNK AND YOU MAY GET LUCKY IF YOU GET ONE TO LAST. I OWN A TRANS SHOP AND ONE DAY ONE OF MY CUSTOMERS CARS DIDN'T START.AFTER A SCAN I FOUND THE CRANK SENSOR HAD WENT BAD SO I ORDERED ONE FROM THE AUTO PARTS STORE.WE PUT IT ON AND IT STILL DIDN'T START.FEARING I JUST WASTED MONEY I RE SCANNED IT TO REVEAL THE VERY SAME CODE THAT IT HAD. TO MAKE A LONG STORY SHORT THEY SENT ME A CHEAPER ONE BECAUSE THAT'S ALL THEY STOCKED AND IT WAS BAD. MAKE SURE YOU HAVE A GOOD SWITCH TO START. CHECK YOUR VOLTAGE AT YOUR ALTENATOR TO SEE WHAT ITS PUTTING OUT?13.5 TO 14.2 WOULD BE PERFECT.14.5 PLUS AND YOU MIGHT HAVE A PROBLEM THERE. WHEN THERE IS HEAT THAT USUALLY MEANS A BAD CONNECTION OVER OVER CHARGING. IF YOU HAVE A SHORT YOU WOULD LIKELY BLOW A FUSE SO I DON'T THINK THAT'S IT. TRY UNPLUGGING THE RIGHT HEAD LAMP THEN LEFT TO SEE IF ANYTHING CHANGES. LET ME KNOW MIKE,TIM.