Engine/Transmission (1994 - 1998) Headlight siwtch again

[rrl989]

I've always heard of the overheated headlight switch problems, but somehow I always thought it did not apply to my truck. After a heavy burning odor, I find the harness connector is melted. The switch seems to work ok ? Will cutting out the connector get me back to normal ?



I'm guessing the terminal must have gotten dirty / resistive in order to "suddenly" generate enough heat for a meltdown. I've been fine for 100K miles. I'm thinking I should just replace the switch and cut out the harness. I know from searches about the Summit harness but I don't really want to rewire at this point. This issue really makes me question DC engineering practices.



Ron

 

[HoleshotHolset]

Ron: The same thing happened to my '94 quite a long time ago. I posted my experience here on the TDR... do a search. There's a Dodge/Chrysler TSB (Technical Service Bulletin) to fix the harness and keep it from ever happening ever again. I got lucky and the local dealer back in MA (Salvadore) sold me the TSB fix with no questions asked.



The local dealers around here would not allow me to buy the TSB fix for my '98 back when I thought I had headlight switch problems with it. (It turned out that the big wire harness that runs under the ABS doo-dads was shorting out and blowing the parking light fuse on a regular basis. )



The TSB fix includes a new headlight switch, new wiring, a relay (to take the load off the switch - and hopefully keep it from melting again), new connector, swanky heat shrink tubing, and very good instructions.



Hope this helps,



Matt

 

[DBentley]

I have been thru the burned headlite switch problem a few times and just noticed today the dimmer doesnt dim no more so i think its ready to melt down again. I took the recal part # that has a relay and plug and sw like holeshot used to the local dealer last time i had the meld down and got a hastle and was told ya couldnt get it. I was willing to pay whatever they wanted but they would only sell me a sw and plug kit instead. Here I am 8 months later and im still messing with it. Does any one know how we can buy the whole deal relay and all ?

Thanks

 

[WDaniels]

FF1063,

The TSB is 918... . I think. And it is only for the 95 and 96 3500. Go to a dealer that you are on good terms with and buy the switch. Mine cost 48. 00 bucks. Not all dealers will sell you the kit. It is easy to splice in. One note tho, use the heat shrink that they provide. It has a special glue built in to seal out moisture and air. It is a must. Hope this helps

WD

 

[rrl989]

re

Thanks for the info

 

[Dual EE]

Head light switch

Mine has been replaced twice in two years by the dealer. The first time because of the recall and the second because the replacement failed 18 months later. Suprisingly the dealer stood behind their product and replaced the second one at no charge :--)









Contact the dealer you might get lucky too.

 

[CarlJensen]

Get the Summit light kit and don't worry about it any more. Runs the lights directly from the battery and sheds the switch load, no more peoblems! For the 9004 bulb it is Summit part number SUM-890030. They also have kits for other light sets. $39. 95 and worth every penny!

 

[rrl989]

I replaced the $55 :-{} DC switch, all is well for now. Will be looking into the Summit harness soon. The old switch was shot, with internal problems which had to cause / contribute to the overheating (lasted 100K miles) Had to mod the melted harness connector / splice in new wires. Their must have been quite a voltage drop across the problem area of the switch as my headlights are noticably brighter with the new switch. Also, I just had spend $50 :{ to replace both of my piaa pro fog bulbs (within a week of each other) so now I can see again Oo. I also got a replacement windshield over the weekend, life is good... ... .....



Ron

 

[Forrest]

Get the Summit light kit and don't worry about it any more. Runs the lights directly from the battery and sheds the switch load, no more peoblems! For the 9004 bulb it is Summit part number SUM-890030. They also have kits for other light sets. $39. 95 and worth every penny!

Ditto ... big time. Great product, easy to install. Sure took the heat outa the switch. My switch was flaking out, but only the dash light portion. I guess the heat was getting to the contacts ... fixed.

 

[DODGEDADDIE]

Replacement Switch,,,,

HOWDY...

I just replaced my switch,,,(the dealer RECALL KIT)... But does any one know where an how does the PIG TAIL that splits into "Y" GOES,,

Also the new switch has an EXTRA SPADE (BLADE CONNECTOR) On the bottom back side??... .



ANY HELP would be a HELP...





THANKS

Mike IN Maine

 

[HoleshotHolset]

Mike:



See if you can get your hands on the dealer service manual for that recall. I was able to make a photocopy of the local dealer's book so that I had directions. The directions are completely painless and well written...



Matt

 

[JTeague]

Here maybe this will help. The overlay harness with the pink w/ red tracer and the black w/ yellow tracer plug into the connector where the wire of the same color would have been. the extra gound wire on the harness plugs onto the terminal on the back of the switch. The original pink/red and black and yellow wires then connect to the overlay harness. Here's the pinout for the rest of the wires.



B1 Red w/ light green tracer

B2 Pink w/ red tracer

B3 light blue

D pin w/ dark blue tracer

H light green

I tan w/ orange tracer

P light green w/ white tracer

R black w/ yellow tracer

U black w/ light blue tracer





Hope this helps.



Jason

 

[Fish On]

ditto on the summit kit, it will save your switch! Lights are a little brighter with it also. Easy install can be done in 30min taking your time.

 

[rbalcom]

i got my replacement switch from auto zone and coated the terminals with liquid copper and did not touch the plug (it was partially melted) and added a relay for the head lights... . i'm currently swapping out trailer and truck tailights for LEDs... should have done this from the onset...

 

[radar doctor]

tks for all the info. Doc.

 

[Dallass]

Just received the Summit 890030 Wiring Harness. My question is: Where does the blue plug connect into? Is it under the battery box and will the battery box have to be removed? Also to plug into the bulb, do you have to remove the headlights? I see that Summit sells Eurolite Super Plasma Bulbs (Style 2004). Will these work? How do they conpare with PIAA? I have to go about 40 miles to buy the PIAA. Dallas

 

[Forrest]

Just received the Summit 890030 Wiring Harness. My question is: Where does the blue plug connect into? Is it under the battery box and will the battery box have to be removed? Also to plug into the bulb, do you have to remove the headlights? I see that Summit sells Eurolite Super Plasma Bulbs (Style 2004). Will these work? How do they conpare with PIAA? I have to go about 40 miles to buy the PIAA. Dallas

Got a couple answers ... The batteries don't need to be removed. Also, you don't need to remove the headlights. The harness could have been just a smiggen longer ... but it fits.

 

[RVPILOT]

headlight switch

I am on my third switch, last one was replaced about 3 or 4 years ago, dealer told me that it was a recall and would be replaced free because it was a safety item. I have since put over 300,000 miles since then and the new version seems to work fine. Stormy