I had an interesting thing happen, the headlight switch on my 1972 Cutlass Supreme pulled completely out of the assembly. I put it back in and it seems to work ok, except that I now notice it is warm to the touch after the headlights have been on awhile. Just wondering if I should worry about this ?

 

You need to check all the terminals, bad connection, Switch should not be hot.

 

The shaft of the **** pushes in and a notch locks into a detent. It's not supposed to pull out without releasing the lock, though.

There is a big wire wound resistor and a ceramic heat sink in there for the interior dimmer function, so it could get warm but shouldn't get hot.

 

Here's a bit more on the rheostat (resistor).

When you turn your lights on, turn the **** past the detent so that the dash lights are full bright.

If the switch stays cool, then you have no worries. The warmth was coming from the rheostat that dims the dash lights. The heat is a byproduct of the dimming.

If it doesn't stay cool, resume trouble-shooting.

 

Might want to disconnect battery till you trace this down.

 

delco headlight switch back then were pretty reliable and we did not have many warranty claims.

Every one a customer or ones that I felt any heat from was the result of loose female connectors at the switch. Also check the connector connection at the main wiring harness. Additionally check the fuse at the fuse box for corrosion. I suggest you use a volt meter and check for voltage drop.

 

I may be wrong on this, but isn't there a small light above or in a hood or something by the headlight switch? I seem to remember one on my 71 Supreme. If so the bulb would make some heat.....