In August of 2011, I noticed a burning smell while using the low beam headlights. Sometimes the smell was quite strong, but I could not find where it was coming from. Until I could find the problem, I decided only to use the car when I did not need to use the headlights. A couple of times I had to use the lights. Eventually, they stopped working and I had to find the problem. When I took the collar off of the steering column, I noticed that the connector to the headlight (combination switch) was melted. There was a greenish/blue corrosion on all of the terminals and it looks like the switch terminals are made of a different metal from the connectors. It now makes sense...two dissimilar metals can cause a galvanic reaction which leads to corrosion which leads to high resistance which leads to heat build up. Current draw on the wire for the low beams is 9 amps. I also have fog lights connected to this wire, but through a relay that only draws 0.1 amps. I called Honda and they state that my VIN is not covered at this point. The local Honda dealer claims that the cause is the fog light wire being connected to the low beam wire. My response is that wire only adds 0.1 amps to the circuit and cannot be the cause of the melted connector...the cause is from the corrosion at the terminals. After some research, I see that my headlight switch (part #35255-S5A-A02) is used on many Honda products that have the same issue with melted connectors. These models include the civic, fit, insight, and CRV. Millions are being recalled for this, but Honda will not include mine. They know there is a problem and have developed a repair kit...part # 35012-S5A-307 to remedy. It includes the switch, a connector, and some wire. A recall campaign needs to be started for the 2003 model year (like mine) and any year or model that this headlight switch (#35255-S5A-A02) is used in. Updated 11/25/11

- Richmond, VA, USA