I have the same problem with my 1997 Ford Thunderbird. This is what I've been told:
This will require the replacement of the turn signal switch and possible connector to it. After the headlight switch is turned on the power goes to the turn signal switch and depending on the setting it then goes to the HI or LO beam headlamps. The connector tends to become overheated and affects the connection and melt the plastic connector.
Hope this helps and good luck with the repair.
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Thursday, February 7th, 2008 AT 9:06 PM