if you use a bypass you are going to need a high amperage switch and a relay with at least 14 ga wire the headlights are using too much amperage for your switch and it gets hot and melts when using a relay it carries all the amps so the switch doesn't have to possibly the factory relay has gone bad and is allowing the switch to carry all the amperage i'm not sure where the relay is located if you have a chiltons or haynes manual you can chase the relay down on the wiring schematics.
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