2nd Gen Non-Engine/Transmission Headlight Switch Gets Hot

[GCurrie]

I noticed when driving at night that the headlight switch on my 99 2500 Sport seems to get pretty hot.



Is there an easy way to transfer some of the electrical load to a series of relay switches to keep the switch cooler? I can't imagine that that much heat is good for the switch.



Thanks for the help



Gary

 

[wtrenholm]

The switch in my '01 gets hot also, but it has more to do with it instrument panel brightness. If I remember right the '99 has the rotary switch also, not the push/pull switch.



There has been some posts on drilling a hole in the left panel air duct to allow some air to pass over the heat sink on the switch, do a search to find more info.



Later,

Wayne

 

[CarlJensen]

Install the Summit relay kit (it's a plug and play type unit) to take headlight load off of switch. It also gives you brighter lights with power for lights coming directly from the battery. You can also cut a small hole (1/4 inch or so) in the A/C duct right near the switch to increase air flow. Do a search on headlight switch heat, or something like that, and get a ton of info. Sport lights are nice but I could not afford them!

 

[WDaniels]

The headlight issue was for the 96-97 3500 but the problem exists in the 2500 from 96 until ???. If the Summit solution is to expensive, go to your dodge dealer you are on good terms with and buy the kit for recall 819. It's about 45 bucks. If you get the dodge upgrade for the headlight switch, make sure that you use the heat shrink that they provide in the kit for your connections. It releases a special glue type stuff to seal the connection to keep out air and moisture that corrode the connections that lead to higher impeadance draw, thus heat. Hope this helps.

WD