Why is my mini eating headlight switches

[TehMonkey]

Any ideas?

The first one died. My other one died tonight, on the way home. Good stuff. Although it was a used switch.

When I pull the switch out, theres some burning on the connector bit. Not good I know. But not sure if this could be causing it.

Thanks all

[GreenV8S]

The contacts in the switch produce heat. Normally the connection to the loom acts as a heatsink and helps keep it cool. If there is resistance between the switch and the loom then instead of cooling the switch it will make it hotter. I've seen relays fail like this when a faulty relay overheats the socket and makes the contacts relax slightly so that the replacement new relay doesn't connect properly and fails too.

[FWDRacer]

You've not fitted one of those sh!t switch illumination kits from W&P or similar? If you have - bingo - there is your problem. The quiescent current draw required for backlighting the rest of the switches + lighting requirement will keep on cooking the main headlight rocker switch.

A more ill engineered piece of aftermarket crap I have yet to find on a Mini. I'll go one further, they are a fire hazard. If fitted - remove immeadiatly and put a new headlight switch in.

[guru_1071]

this is a common problem often caused by people overloading the switch with stuff like the illumination kits, spotlamps or uprated bulbs.

the other thing to check is that all the earths etc are good as poor earths will cause the switch to heat up.

a mate of mine had this problem recently, and after a light faliure on the motorway he brought it round for me to look at.

as a quick fix i added a wire loop into the headlamp feed with a fuse inside the car, that was we figured if the fuse popped, it would do it beofre the switch really got hot, then he could stick a bigger fuse in to get him home.

i also swopped the cheap switch for a decent one (this was on a mk1) and it hasnt done it since.

[DanGT]

If you have added anything eg spot lights to the circut the hole lot will work off the switch OR there is an extra load due to a fault OR you just had a bad switch. If you have added extra load, wire in a relay so the switch switches the relay and the relay takes the load.

[timelord]

Been down that dark road with my Min lately, non-illuminated switches, no extra spots,'cos the switch burnt out the pins got hot annealing the contacts in the plug making it loose its spring. Or to put it simply the plug's knacked, the only place I've found to buy plugs is Autosparks no Mini supplier keeps them. Tip for fitting new ends on the cable is pull plug out and pinch cables with small mole grips leaves both hands free to make off cable ends.