Well I took the switch out today. There was noticeable heat marks on some of the pins for the switch. The plug is a little deformed from the heat. I was going to try cleaning the pins, but I took some of the screws out on the switch and before I knew it I was left with a bunch of springs and parts that I had no idea where they go. So off to my local junkyard. Spent 15 minutes in 200 degree car pulling a switch and they tell me $40 when I come to the office with it. I LOL'd all the way out the door telling them that is the price of a brand new ACDelco switch and that I will never be back, and then my floor mat must of accidentally got caught on my gas pedal in their parking lot

(this use to be a great junkyard. either how they manage it or the owners have changed in the last few years. use to be able to walk out with a box full of parts for $50, not just 1 switch. not the mention quality of service, i wont be back)
Then off to junkyard 2, I called them since I have never been there and they said $25 and they pull it. Figured I'll bite since I won't have head lights otherwise. Went and got it and tested it and it worked great. Got back home and started putting it all back together but before I finished I tested it again and had the same problem! Pulled it back apart and test it again and then all the lights work.
At this point I'm thinking I have a good switch but something else somewhere isn't working right. Or I could of just gotten another bad switch? I was thinking maybe something in the plug might be shorting out because it has melted a little bit? Opinions?