A couple of days ago my headlight switch started acting up. I'd turn on the lights but the dash lights wouldn't come on. I can wiggle the switch and the dash lights will come on.

The next day I started noticing a "hot" smell, you know the smell that a wires insulation gives when it's hot. After some troubleshooting, I figured out that it's only when the lights are on. I can hear my alternator load up when I turn on the lights! The fuses aren't blown, the 10A fuse that controls the dash lights is kinda melted but not blown! I noticed one small wisp of smoke come from somewhere around the steering column but I can't find the hot wire.

Would a bad switch cause this or have I got bigger problems?

 

Take a wire checker and make sure that all the wires to the lights are not broken or cracken inside of the houising. The replace the fuses to double check. Also could the dash lights not be coming on becasue you bumped that little dimmer switch to off. That happened to me and it took me 5 min to figure it out.

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It isn't the dimmer... they'll come on if I wiggle the switch. I just think it's too much of a coincidence. I just don't understand why the fuse isn't blowing... maybe I got a defective fuse!

 

If the switch is not making good contact,
The resistance is increased which increases the amount of current needed to feed the circuit..
and That is why it is getting hot...Clean the contacts inside or replace the switch..

 

That's what I'll do, I'll try cleaning it first.

What is puzzling is that the fuse is all melted but not blown!