recently i pulled on the headlights and started smelling burning plastic and after pulling the headlight switch i discovered that the green wire coming out of the "H" post on the switch is the one getting hot. i have replaced the headlight switch, the pigtail going into the switch,and the dimmer switch. I have checked all wiring in the engine compartment as well as in the cabin. the only thing i havent checked is the firewall. is it possible this could be the problem area?

 

Have you done anything to the headlights? New bulbs? Hotter bulbs?

Unfortunately, it's a common problem with the 2nd gens. The headlight switch is easily overloaded. Both Geno's and LMC sell a kit to take the load off of the switch.

Here's the one from LMC:

http://www.lmctruck.com/ICATALOG/DE/full.aspx?Page=20