How do I replace a headlight switch

The best I can offer is for a 1996 caravan:

REMOVAL

1. Remove steering column cover.
2. Remove over steering column bezel.
3. Remove left end cover.
4. Remove screw at left end of cluster bezel and headlamp switch.
5. Remove screws holding cluster bezel to instrument panel from each side of steering column.
6. Disconnect clip holding cluster bezel to instrument panel from above right vent louver.
7. Separate cluster bezel from instrument panel.

Disconnect wire connectors from back of the bezel.

INSTALLATION

1. Connect wire connectors into back of the bezel.
2. Place cluster bezel in position on instrument panel. Use care not to place hands on louvers.
3. Connect clips to hold cluster bezel to instrument panel. Use care not to add pressure on the A/C louvers to seat the cluster bezel clips.
4. Install screws to hold cluster bezel to instrument panel on each side of steering column.
5. Install screw at left end of cluster bezel and headlamp switch.
6. Install left end cover.
7. Install over steering column bezel.
8. Install lower steering column cover.

unscrew the headlight bezel around the bulb and unplug then plug new one in,then replace the bezel and screws

Remove the trim bezel around the instrument cluster. You may also need to remove the instrument cluster as well. there are two bolts securing the switch housing to the bezel.

1.Park the vehicle on a smooth, level surface and set the parking brake. Tilt the steering column to its lowest position.
2

Place your right foot on the brake. Put the key in the ignition and turn it to the "On" position, but do not start the truck. Shift the gear shifter to its lowest position.

• 3
  

Grab the dashboard bezel that goes around the radio and the gauge cluster with your hands, and pull it toward you to release the clips that hold it in place. Then unplug the wiring to the headlight switch and any other accessories on the panel (which change depending on what model of Sierra you own), using your hands. Pull the bezel away from the dashboard, and put the Sierra's transmission back in "Park."

4Place the dashboard bezel face down on a work surface. There are two tabs on either side of the dashboard bezel holding the headlight switch in place. Use the flat-head screwdriver to gently pry these apart one at a time, then pull the switch out of the bezel. Be careful, because depending on how brittle your dashboard is, you can break these tabs fairly easily.

5Push the replacement switch into the dashboard bezel. Then put your foot on the brake again, shift the truck into the lowest gear, and reinstall the wiring to the bezel using your hands. Push the bezel onto the dashboard to secure the clips, then put the truck back in Park and turn off the ignition

Hello
You will need to replace the switch and the connector to the switch, a new switch will not cure the problem and will quickly overheat and burn out again unless the burnt connector is also replaced. You will need to contact a local Chevy dealer for the replacement headlight connector
To replace the switch follow these instructions:

1. Park the truck on a level surface and set the parking brake. Place your foot on the brake then put the key in the ignition. Turn the key to the "On" position but do not start the truck.

2. Shift the automatic shift lever to the "1" position and tilt the steering column to its lowest position using the tilt adjustment on the bottom left side of the steering column.

3. Hold the bezel/trim around the instrument cluster and pull it towards you to release the clips holding it to the dashboard. Work your way around the bezel, pulling it as you go, until it's only connected to the dash by wiring. Unplug those wiring harnesses from the back by hand then put the gear shifter back into park. Bring the bezel to a table or counter that you can work on.

4. Turn the bezel onto its face. Locate the headlight switch which should be on the lower right corner of the bezel. There are delicate plastic fingers that hold the switch to the dashboard. Carefully pry these away from the switch with the flat head screwdriver in one hand while pulling the switch away from the bezel with the other until it's free.

5. Push the replacement switch into the bezel until it clicks into place. Then bring the bezel back to the SUV. Put your foot on the brake and shift the shifter into the "1" position again. Plug in the connections on the bezel then push the bezel into place on the dashboard until it clicks. Put the shifter back in park, tilt the column to its desired location and turn the ignition off.

When replacing the connector cut one wire at a time and transfer it to the same position on the new connector, solder and shrink tube each wire, take your time. Remember one wire at a time.

Your headlight switch needs to be replaced. Here's the section from the maintenance manual.

Headlight Switch REMOVAL & INSTALLATION

1996 Dakota

1. Disconnect the negative battery cable.
2. Remove the steering column cover and remove the instrument panel bezel. Two screws are hidden behind the steering column cover.
3. Remove the screws from the headlight switch bezel, pull the assembly out and disconnect the wiring.
4. Remove the nut retaining the bezel to the bracket. Depress the spring button on the right side of the switch and remove the headlight switch knob and stem.
5. Remove the spanner nut and remove the switch.
6. The installation is the reverse of the removal procedure.

Check both headlight bulbs, check for power and ground (the ground wire is black). If no power either wire to ground remove the headlight switch in the dash. The bezel around the cluster just pulls away. Check the connector to the switch. The large red wire (power) or the black (ground) may be burnt. Repair if possible or replace if melted. There isn't a headlight fuse. If only one setting works (eg. hi beam only both sides, no lo beam) then the dimmer switch is at fault. Its part of the turn signal switch.

Removal & Installation (If dimmer is on headlamp switch area) To Remove:
Instrument Cluster Bezel removal

1. Remove or disconnect the following:
   • The instrument cluster bezel
     1. Unsnap the switch from the housing
   • The electrical connectors Headlight switch removal
     
     
   • The switch

To Install:

1. Install or connect the following:
   • The electrical connectors
   • The headlamp switch by snapping the headlamps switch into place
   • The bezel to the instrument panel
2. Operate the headlights to check performance

It's talking about the headlamp bezel, the bezel is a band that goes around the parimeter of the lamps and holds it in the "headlight bucket". The screws may be a T15 Torx, if it looks like an allen head but an allen won't fit try a Torx driver.

Sealed Beam Type

1. Disconnect the negative battery cable.
   
2. Unfasten the headlight bezel attaching screws, then remove the bezel.
   

Remove the headlight bezel

To avoid turning the vertical or horizontal aiming screws, refer to the illustration before removing the headlight retainer.

1. Unfasten the headlight retainer attaching screws, then remove the retainer.
   

Remove the headlight trim screws then...


... pull the trim off while holding the bulb

4. Pull the headlight out, then carefully detach the electrical connector.


Pull the bulb out far enough to disconnect the wiring


To install:

1. Attach the electrical connector to the new headlamp.
   
2. Place the headlamp into the socket.
   
3. Install the retainer, then tighten the attaching screws.
   
4. Connect the negative battery cable, then turn the headlight switch on, to be sure the headlights are operating.
   
5. Install the headlight bezel and secure using the attaching screws.