Okay, from your description it sounds like the issue could be in the body control module itself. On that truck the relay goes to constant power, then it feeds the two fuses. From there it goes out to the headlamp bulbs and then through the dimmer switch to ground. You said that you made jumpers that went from the battery to the headlight fuses and that made the lights work? That would bypass the power relay and its control wiring that comes from the body module. It also shows that the dimmer switch and grounds are not the problem as those are after the lamps. So, it has to be on the switched relay side, it isn't being turned on. Attached is the wiring diagram. Being an intermittent it may take a bit to track down. I would start at the relay and see if the relay control voltage is on pin 85. If it is missing then look at the headlight switch itself.
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Sunday, March 26th, 2023 AT 3:24 PM