Hot Headlight Switch
 

My duaghter said that the headlight switch on her '96 gets very warm when she drives with the headlights on. She said it gets particularly warm around the wheel that dims the dash lights. Is this normal? I assume some warmth is normally, especially around the dimmer since it is probably a variable resistor, but she said it is getting quite warm. Note that since it is a '96 it has the older style dash design with the older style headlight switch. Thanks. I did some forum searches but didn't find too much.

Very good diagnosis on Your part ! .... If You run the dash lights dimmed down there will be more heat produced by the rheostat as it works to shed heat while reducing current/voltage - i.e. normal operation :)

would it be possible or even feasible to convert the old style (my 95 gets a bit to warm for my comfort as well) to a newer style?

Well ... sure anything is possible but the wire harness plugs , molded switch mount locations ect are all different ... I was toying with the same idea of upgrading a '95 Blazer , already have all the "new" parts pulled to do it even ... in the end all I did was remove the light switch assembly set up and used some radio shack TV tuner cleaner/lube spray to clean the switch contacts and dimmer . Works like new and fixed the headlight on warning chime . Sprayed some in the ignition switch and now the key left in warning works too ... I never missed that "feature" though