LUVTruck.com

So I've managed to locate where I think a problem is in my wiring. Right at the wire connections behind my headlight switch, they get super hot. Like burn to the touch if I pull them apart and touch the contacts. ONLY if the headlights are on. Running lights everything is fine, lights in the dash are nice and bright, fan blows correctly. But when I pull the switch back to turn on my headlights, voltage drops, lights dim, windshield wipers slow to a crawl, and the fan almost completely stops running. I'm assuming that means something is wrong with the wiring contacts? Anybody have any experience with this?

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You have a heavy load or possibly a short in the headlight circuit. May even be in the headlight bulb itself. Just unplug each headlight in turn and see if the problem clears. If pulling the headlight plugs does not clear it you are stuck with following the circuit wiring itself.

Headlight wiring is a little difficult to trace without a diagram. I've attached a schematic for the 1980 LUV if that helps.

Mine gets hot too.

If you have whatever wiring issue while the headlights are off, then that's not your issue. If you what to fix the issue, you could put relays on the headlights and running lights circuits.

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1979 4wd Mikado. G200, Gemini 250 Turbo, Clive Cam, Offenhouser Intake, JE Pistons, maXspeeding Forged Rods, Blow Thru Weber, Trooper 5spd, Intercooled