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OK, after a lot of trial and error and cleaning grounds all over the truck, it turned out to be a faulty connection in the headlight bucket. Looks like vibration had caused the connector to wear through on the inside of the assembly.
In the end I replaced the whole thing and it works like it should now. Glad to finally put this thread to an end.
Thank you for the work and anguish on the headlight question. I have a similar problem with headlight on my 715, so now have a better idea where to go back and look harder. I too have changed the 3 way and cleaned grounds but the headlight does not last long, so am thinking your connection or a bare wire somewhere may be the trick.
I feel your pain, electrical problems are a nightmare for me, since I have little knowledge of all that at the moment. Replacing the entire headlight bucket finally worked for me, hope it will solve your problems as well!
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