recently i pulled on the headlights and started smelling burning plastic and after pulling the headlight switch i discovered that the green wire coming out of the "H" post on the switch is the one getting hot. i have replaced the headlight switch, the pigtail going into the switch,and the dimmer switch. I have checked all wiring in the engine compartment as well as in the cabin. the only thing i havent checked is the firewall. is it possible this could be the problem area?

It's possible. The connectors at the firewall block are pretty small, and when I looked at mine there was some corrosion, possibly because of water running down the wiring loom into the block.

You might want to consider using relays for the headlights, because the stock wiring and switches are sort of "bare minimum". I burnt up both headlight and dimmer switches, too, but I was using 130W H4 bulbs. You definitely need relays to do that.

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Larry

i checked the firewall connection today and it all looked real clean so i am lost again.[:@]

Could be something inside the switch causing it to do that as well

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'95 Dodge Dakota 4x4 5.2L club cab - 224kmi - Dual Exhaust, Filtercharger, Duals, sh--load of lights
'92 Dodge Dakota 4x4 3.9L club cab - 166kmi - V8 TB, '95 grand Cherokee Self-Dimming mirror - soon to have new exhaust

inside what switch? igniton switch, dimmer switch, headlight switch.

Ah, the burning/melting headlight switch.
Replacing the switch is only a temporary patch on what is the correct solution - which is to install relays for both the low and high beams.
The problem is that there is too much current running through the headlight switch. Running too much current through wires (or a switch) that isn't ment for that load results in fires, surely something you don't want to happen to your truck.

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Current ride: Belleville 220 DES ST - leather, reinforced front end, tan color. Runs on 'alternative fuel'
1996 Dodge Dakota
1986 Honda Civic CRX

the h wire on the headlight switch is head lights take 5/16 bolt out of the fire wall plug an check for corrosion they turn green an rot out. water & salt gets in the rubber cup.mine rotted out and messed up 5 or 6 things in side the cab.