2nd Gen Non-Engine/Transmission 1996 12 valve headlights only work when I pull the multifunction switch

[AndrewD13]

I'm new to posting on this forum so go easy on me. I've been searching for quite some time for an answer to my problem but have yet to find a solution.
I did a complete overhaul on a 1996 Ram 2500 ECLB 4x4, body work, paint job, suspension work, performance mods, heater core, etc. I had headlights that worked as they should before the overhaul. A few months later I have the project done and started it up for the maiden voyage and a few minutes after startup smoke starts filling the cab, disconnect battery terminals, stand by with a fire extinguisher for a few minutes then I started my research. I ended up replacing the melted headlight switch and wiring. I retest and the lights work for a couple minutes, more smoke, shut truck down, disconnect terminals, pull apart headlight switch, all is well. I pulled the bottom dash panel (under the column) and nothing, pull headlight switch out and the lights worked but slowly flickered out along with the door buzzer (because the door was open) and I see smoke coming from a bundle of wire, I pulled the bundle apart and found a black w/ blue wire coming from below the ignition that had melted all the insulation off and broke the wire in two. I cut the wire at the plug and folded the remaining wore over itself and electrical taped it. No more smoke but my headlights now only work when I hold the multifunction switch back (to switch from hi beam to lo beam) so I replaced the multifunction switch, still the same result. Brake lights, cab marker lights, reverse lights, blinkers, hazards all work as they should. I'm stumped. Any help is greatly appreciated.
-Andrew

 

[klcammie]

First welcome, there is a lot of good info here. Second you need to go to settings and fill out your signature so we can see info on your truck. I'm not real versed on 96 trucks, but the wire blk/blue that broke in two, if you put power [12 volts] to the end of it does your lights work. It sounds as if you have a direct short in the headlight circuit.

 

[BigPapa]

Here's the diagrams on your Blk/Blu wire in the steering column/headlight switch area:

 

[AndrewD13]

Thank you for the quick reply. I haven't been able to work on it but I will put power to the blk/ lt blu as soon as I get a chance. I added a signature. I think it worked?

 

[klcammie]

Also check out Big Papa's post.

 

[BigPapa]

I will put power to the blk/ lt blu as soon as I get a chance.

I wouldn't do that if I were you without some further investigation.

The two diagrams I posted are the only two for your truck that show a "Blk/Lt Blu" wire. One shows a "Warning System" circuit with a "Blk/Lt Blu" wire around the headlight switch and the "Key-In-Switch/Halo Light" part of the ignition switch. Putting power to this wire probably won't hurt anything.

BUT,

The other diagram is for the airbag circuit and plainly shows a "Blk/Lt Blu" wire going to the driver airbag in the steering wheel. Putting power to this may result in an airbag deployment.

 

[Slow Six]

It was a long time ago but I had a similar problem with my 1994 truck. If I remember correctly I had to replace the head light switch. They were known to crap out.

 

[SAndreasen]

My headlight switch burned up in my 95 and the headlights would only work when I pulled the multi function switch

 

[BigPapa]

I ended up replacing the melted headlight switch and wiring.

It was a long time ago but I had a similar problem with my 1994 truck. If I remember correctly I had to replace the head light switch. They were known to crap out.

My headlight switch burned up in my 95 and the headlights would only work when I pulled the multi function switch

He said he'd already done that.

 

[klcammie]

I wouldn't do that if I were you without some further investigation.

The two diagrams I posted are the only two for your truck that show a "Blk/Lt Blu" wire. One shows a "Warning System" circuit with a "Blk/Lt Blu" wire around the headlight switch and the "Key-In-Switch/Halo Light" part of the ignition switch. Putting power to this wire probably won't hurt anything.


BUT,

The other diagram is for the airbag circuit and plainly shows a "Blk/Lt Blu" wire going to the driver airbag in the steering wheel. Putting power to this may result in an airbag deployment.

Yes I agree I didn't look close enough at the second diagram. BigPapa you are correct air bag deployment would be a bad thing.

 

[sgmans]

I'm replacing my headlight switch on my 94 3500 4wd. I ordered the new switch from Geno's garage, but there is one black wire that connected to a terminal on the case of the old switch, but that terminal is missing from the new switch. With the new switch installed the headlights work fine, but the parking/running lights do not work. If I touch that black wire to the case of the new switch, everything works as it should.

Should I attach the black wire to the case of the headlight switch or did Dodge leave that terminal off for a reason? I have searched and couldn't find this specific issue, was wondering if anyone else has run into this and how they solved it.

Thanks for your help.