a different headlight issue not working
 

As I had a passenger light not starting, my surge on internet mostly went about the headlight switch. Although I did have the same idea, I still went in to look for other mishaps as my gut told me more to look for misalignment.
It turned out that the little clip on the axle where the light unit locks with, was out of it's place and therefore the bushing of that axle was out and had more play then usual.
So far, after putting back the way it supposed to be I have had no problems any more.

http://forums.pelicanparts.com/uploa...1592937711.jpg

http://forums.pelicanparts.com/uploa...1592937933.jpg

part 22 was out of place and part 23 slid away and gave the lock axle(23) wiggle room to not fully connect the headlight.