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Engine/Transmission (1998.5 - 2002) Backup Light Switch on the 5600

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Wiredawg

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I did a search and did not find much about 5600 backup light switch failures. My 02 truck has 97K miles on it and is on the third one. I just replaced the backup light switch again. I meant to cut the first one open, but lost it. I cut open the second switch and found the contact inside to be extremely oxidized. I expected it to be burnt. The connector can rotate in the switch housing, so it's possible rotating it might clean the contacts. Another possibility is drill small hole in plastic connector to spray contact cleaner inside. Worst case, pay $68 for an new one.



I do have bright 100W backup lights mounted on my headache rack, but I still like keeping the stock stuff working too.



Wiredawg
 
Wiredawg, I have no idea how this set up is wired, but IF you have your auxiliary light wired through this switch it may be too much for it. If your aux lights are wired to factory switch and you keep killing them,(i know you said they were not burnt) add a relay to draw smaller amounts power and not draw so much current.



You may have the 100w lights on a separate switch, but I am just going off of your first post. Any more data on your trucks wiring and we could figure this out.



Dave
 
Dave, The backup light circuit is completely stock; My aux backup lights are a separate circuit w/ a relay and a lighted switch in the cab.



I become suspect of a part when several dealers have them in stock, indicating a possible trend failure. Interesting I haven't seen this problem in the TDR.



Anyway, thanks for the comeback



Wiredawg
 
I have 71K on my truck and the backup light switch is out again. I have already replaced it once and just recently threw the old switch out when I was cleaning up the garage. Wish I had kept it now for an autopsy.



I am seriously thinking about by passing it and installing a toggle switch in the cab. Does anyone have any insight or experience on these switch failures?



Or are we the only two having the problem?
 
They are actually relatively common failures, and not just on these trannies but all the dodge truck manual trannies. I had several go bad on my dakota way back when, and have lost one already on the cummins. I can only assume most people just don't bother posting about it.

mishkaya
 
I've replaced one switch so far and I'm at 173K. San Antonio has a great dyno setup at Fuel Injection Specialties. Is that where you got your dyno numbers from? I'm going to try another dyno run this winter and shoot for 500\1100.
 
My original failed quite some time back - I replaced it, then cut the OEM apart, cleaned the contacts, and saved it for a spare after using JB Weld to re-assemble it. Haven't had any more problems, so don't know how long the replacement or rejuvenated one are good for.
 
I had to replace mine at around 71,000, they are not cheap. Like an idiot I threw my old one away instead of keeping it & doing what Gary did to his. Oh well live & learn.
 
DPrew,



Haven't dyno'd in SA before... Numbers posted are from May Madness '04. They are consistent w/ the ones in Kerrville in '03. I'm done w/ perf mods... the stacked TST PM3 on the Edge EZ is killer on the low end, but doesn't do a lot on the top end. We shoud hook up sometime.



PM me if interested.



Wiredawg
 
When I had to replace mine some time back, I took the failed original apart to see how it worked, and what had failed. Turns out to be a very simple design, and easily cleaned - but getting it apart without irreversible damage, and then back together for reliable operation is the hard part - but not really bad. It's a good idea to carefully apply alignment marks to the base and plastic switch section prior to cutting for later reassembly.



I carefully cut the plastic section all around with a hacksaw just above the metal shoulder of the threaded portion - being careful to not cut too deep and damage internal components. Once apart - sorry, no pics of the innards - it was quite obviously a simple design, and the pitted internal contacts were easly cleaned up and renewed. Mine appeared to have suffered from lube contamination - probably a poor or failed seal between the transmission and switch internals - and the oil wetted contacts subsequently were no longer making proper electrical contact.



After cleaning up the switch contacts, I carefully reassembled the switch section to the base, and tried the operation of the switch to see if the amount of material removed from the sawing process for disassembly had interfered with proper operation of the switch - would it still complete proper on/off cycles. It did, so I then carefully applied JB Weld, clamped the 2 sections - carefully realigning the 2 halves as they had been originally, and that was it!



Others trying this, should be cautioned to CAREFULLY apply the JB Weld, using only enough to provide a good joint - but not so much as to "squeeze" inside the switching section and prevent proper movement. Likewise, excess external weld must not interfere with the ability of the plug to seat properly - but excess on the outside can be easily filed or otherwise removed as needed.



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Obviously, if oil intrusion continues with the "repaired" switch, it may well fail as it did originally - although if the contact action is solid enough, it might not be a major issue, since the contact pressure now IS slightly increased with the removal of material in the disassembly process, and reassembly. There is little danger with a failed switch like mine as to lube leaking clear to the outside - at least as long as the rejoining process is done properly, since the plug contacts are completely molded and imbedded into the plastic section, with little likelihood of leakage to the outside.



If the removed material is so much the the switching operation becomes erratic - most likely not switching to the "open" position because the 2 switch halves are now too close together, they can be shimmed with small appropriate pieces to restore proper spacing, then JB Welded.



As far as I'm concerned, this was more a simple experiment, and while it seems the switch is quite functional, I'll only keep it as a backup, and for temporary use if needed, until a new replacement can be obtained - and that's of some value, since we live in a somewhat remote area, and replacements aren't always fast and easy to obtain...
 
Mine has been out since about 40K, I'm at 91K now and have yet to replace it



One of these days I'll pick one up



As I recall, 40K was about when my original failed too - cost in the area of $40 as I recall - I hear they are now more like $80, so more worth the effort to repair a failed one... :eek:
 
I should pull it apart someday, but I have lights in my rear bumper on a seperate switch so I haven't worried much about it.
 
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