melting headlight switch

[Calvin Krug]

Yes, this is a common problem on the 4K.  It arises from the fact 
that the headlight wiring is a little undersized for the job, and all 
that current runs through the switch.  The solution is to wire in a 
pair of relays under the hood, so the switch only carries the power 
to trigger the relay.  The headlights will get their power directly 
from the alternator, through the relay.  As a bonus, you'll even get 
more light output from the bulbs, due to less voltage drop.
I'm certain that there are several links to help you with this on the 
audifans website.  Or you could ask me, as I did this to my 4K last 
year. I'll walk you through it.  It's not too tricky if you've done 
any electrical work on a car.  Good luck

Calvin Krug.
-- 
Before I criticize a man, I walk a mile in his shoes. That way,
if he gets angry, he's a mile away -- and barefoot.