Headlight switch and plug

[John Martines]

I know someone here has done this maybe more then once! I have no headlights,All other lights work fine. I have a new headlight switch and dug in to it after work. Here's what I have the switch melted to the plug, I've heard this of this before, So does the plug have to be replaced? I'm posting pictures of the plug and switch. You can see in the picture of the plug where it's melted.

 

[Stanbery]

I had this happen once on my 2nd gen, and once on my 1st gen. Both times it was after I tapped the one of the wires for my gauge lights. I didn't have to replace the switch, but I did it for safety reasons as I didn't want another meltdown. Everything has been fine since then.

 

[John Martines]

So your saying to replace the plug as well? And if so how hard is it? And I assume it(plug) can be had from Dodge?

 

[blacksheepdiesel]

John,

Good luck on finding a plug - and if you do find one I bet it ain't cheap.

Mine plug looked very similar to yours. I simply cut off the melted portion of the plug and put a new female spade end (preferably with a shroud on it) on that wire, put the plug back on, then the wire by itself making sure it would not make contact with anything else. Works perfect!

Godspeed,
Trent

 

[Stanbery]

Yea, I forgot to mention that part... They're not available from Dodge unless you buy the whole wiring harness... . For the 1st gen I just went to the junkyard and got one and soldered together, for the 2nd gen I did what Trent did. And like he said, make sure you get the ones with the protection.

 

[dpuckett]

Most times, the extra heft of the dually running lights burns them out, but there have been more lately that have just burned out/ up. I put relays on the headlight circuits (also makes them brighter to boot), along with the tail light circuit. On my old 91, I installed a switch, so I could flip the tail lights on and off at will and be like the big rigs



Daniel

 

[Philip]

Dodge does sell the replacement plug. I have bought two in the last 8 years. The Dodge switch lasts longer than a aftermarket switch also. I replaced aftermarket switches once a year. The Dodge switch was good for 2 to 3 years.



Last one I bought the plug and new switch was around $65. or so.



Install a relay and move all the tail light load off of the plug and switch. Then you won't have that problem agin.

 

[tx_fireman1525]

Install a relay and move all the tail light load off of the plug and switch. Then you won't have that problem agin.

I need to do the same on mine.



You know i always hear when this topic comes up that the extra lights on a dually causes this. Well mine is a 3/4 ton, and i dont have any extra lights at all on mine, but yet i have the same problem. Anyone have any ideas?

 

[Philip]

If you have a trailer plug on the truck. It pulls the power for trailer lights from the headlight switch also. There is the extra load to burn out the terminals.



This is the # for the Dodge replacement plug. 4728204 = $83 list price.



Most Dodges used the same headlight plug for these years. The vans and large body cars. So finding one in a junk yard shouldn't be to hard. The 94 trucks also used the same plug. I am not sure when Dodge changed this plug.

 

[dpuckett]

Mom's has a plug from a 96 van, if that helps broaden your search options.



DP

 

[Stanbery]

dodge sells the "switch", not the "plug"... the plug is part of the the cab wiring harness and is not available for purchase seperatly.

 

[Philip]

dodge sells the "switch", not the "plug"... the plug is part of the the cab wiring harness and is not available for purchase seperatly.

ROFLMAO



I have replaced two plugs on my truck in the last 8 years. Both plugs came from a Dodge dealer. If you take the number I posted and run down to your local dealer he will show/order you one. BTW I stoped by my dealer and got that number this morning. If your dealer can't find the number then they need better parts men.



They had one in stock also.

 

[John Martines]

Thanks guys a dealer near me has a plug in stock so tomorrow morning I'll pick it up. The relay for the rear lights? Where did you get it? Does it just go in under the dash in line to the rear lights? Thanks again we'll see how it goes!

 

[csnider]

Before you go and just replace the plug and switch( it will get hot again) do what I did and get this upgrade kit from the dealer . it's for 94 and up but it works fine in ours too. . it puts a heavy duty relay in the headlight or running lights circuit ... ...

Here's a article about the kit. . It's a complete kit ... part#CAJM8190



http://dodgeram.info/tsb/recalls/819.htm

 

[John Martines]

Dang! I went and got the plug this morning. I'll see if they have or how much the kit is. I haven't opened the package yet so hopefully I'll be able to exchange it for the recall kit. Thanks for the link and the info,You guys are great for info and helping keep the 1st gens alive.

 

[Philip]

Before you buy that kit call a local parts store and see what a 5 pin bosch relay and plug would cost. The plug you bought from Dodge and a aftermarket Bosch relay will most likely be cheaper.



That Dodge relay kit is a 4 pin relay. If the relay fails for whatever reason you have to cut and splice to wiring to make fast repairs if your on the road some where. With a 5 pin relay you have a normal open and a normaly closed terminal. Just move the wire over to the unused set of contacts and be on your way. You would use the normaly open contacts for the light to fuction with the head light switch. The normaly closed set would have the markers on all the time.

 

[John Martines]

I hate to keep asking questions about this but I'm a dim light in a dark shed. The only relay I can find is a Napa truck light 40amp 5 pin. Will this work? I can't find a plug for it. I can use slip conectors on it. Does this only go to the marker and rear lights? I've got to get this back together as we have snow on the way.

 

[blacksheepdiesel]

John,

Since time is of the essence I would say go ahead and wire up the relay for just the marker and rear lights for now. You can always change it later.

Godspeed,
Trent

 

[Philip]

That 5 pin will work. Just do your marker and tail lights on it. The spade connectors will work. Mount it inside the cab and then you won't worry about weather shortening the life of the relay. Install it in a easy place to get to also. Then later on if you need to troubleshoot for any reason you can get the the relay easy.

 

[KOG]

An alternate to the relay is switching to LED lights for tail, marker and trailer. Not as cheap up front, but the other advantages are also significant. I've been using headlight relays for many years on stuff with aero headlights to improve light output, but haven't had to use a relay on the tail/running circuit. I know that towing a trailer like my 9T gooseneck with four more taillights, center makers and 6 side markers added to the front and rear markers plus side markers on the truck adds a huge load to the switch compared to the two taillight bulbs on a "normal" P/U.