2nd Gen Non-Engine/Transmission Headlight switch again!

[QRTRHRS]

There has been more than one 2500 with headlight switch problems. One thing I don't like is the size of the wiring. Not much margin for error with the wire sizes.



Bear with me for awhile on the schematic. My wife has a flatbed scanner but I don't think she knows how to use it and I never have. If I can figure it out, I will post what I did.



Like I said, I have it in use but it is not done yet. Once we get through the holidays, my friend at work is going to help me refine it more. I have a 20 year old degree in electronics technology but never worked as a tech so by myself, I get into trouble.



That and 24 days are never long enough for me.

 

[Hummin Cummins]

Back TTT

I'm getting a list to start this project myself. I melted one on my 95. Just warped the black connector a little at one pin. I put in a new switch, and all was good for about 3 months. Now it melted to the point it scared me. I can replace the black plug, but since I have to pull out the wires anyway, I'm gonna put in toggle switches. I think 3 will be enough to do the job. One for headlights, one for markers, and one 3 way to switch between cargo and dome light.



What I'm not sure of is how heavy a toggle to get. The heaviest I think are 30amp.



My 95 service manual shows 2 headlight outputs

3 Fused feeds

1 Ground

1 marker output

and key-in / doorjamb sense (2 wires)



The headlights and markers should be easy. Power in / power out

What happens with the sense wires. They act through ground, so I guess that the three way switch would come in here.



I have had problems with the 2 switches from napa. I'm done with that mess.



Anyone else done this since the last post?

 

[RJ2]

I put the 2 relays and 10 gauge wire to the headlights , with leds for clearance lights ,not much running through the switch.

The headlights are much brighter.

 

[Hummin Cummins]

Called the dealer, tried to sneak it in the recall with no luck. The did have the recall kit there. I bought it for 35. 00. Also found out there are 4 other open recalls on my truck. I didnt think I could do the wiring with toggles for 35. 00 in materials and beer.