Greetings jfletch,
I washed your problem description against the headlight circuit theory description in the '94 Electrical Diagnosis FSM,
and I think I have an idea of what's going on. But before I write that, first here's what I read:
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So from here it looks like the problem definition is as follows:
* No problem observed with the headlights off.
* No problem observed with the High Beams on.
* Replacing the headlight switch did *not* solve problem. (ie: verifying that self-resetting circuit breaker
in original headlight switch was not tripping too soon. NOTE: Correlates with high beams not blowing.)
Given the above, the problem description is that somewhere in the low beam circuit (only)
excess current is being drawn. A close inspection of every inch of the low beam wiring between
the headlight switch and both low beam bulbs should uncover the source of the fault.
A: In the headlight switch. But thanks to the headlight switch replacement, instead of the
circuit breaker being the perpetrator of the fault, an excess current draw
on low beams only
is the root cause, and both thermal circuit breakers in both headlight switches were working
as designed.