2nd Gen Non-Engine/Transmission Headlight switch melting

[plangone]

My headlight switch gets hot and starts to melt after a while and I am not sure what lights are causing the overload. It is the same whether I am hitched up to a trailer or not, and is the same whether headlights are one or not. I had replaced the switch itself with a NAPA unit several months back when I could not turn on the lights consistently. I just pulled the switch out yesterday and found only one terminal seemed to be bad. It was the pink w/red stripe wire. I pulled it off and could not find anything that stopped working. Does anyone have any idea what this wire does? I imagine there is a problem in that circuit causing the high resistance/heat problem. I know there was a recall on some of the 3500 trucks, not sure if it applies to my '95 2500. The recall work might not even help if there is something going on with that pink / red wire circuit.

 

[crabman]

Go Here:

Headliam switch recall

 

[WDaniels]

plangone,

Sorry for not responding sooner. I too have had this problem many times on my present truck. What apparently has happened, DC used as light as a wire that they could for their wiring harness and sometimes the load is to much and melts the headlight wire. Some of the 2500's were covered by the 819 recall. Depends when your truck was made. If the dealer will not cover it get the parts kit from recall 819. I paid 44 dollars for it. It is not hard to replace, just a little time comsuming. Make sure to use the heat shrink that they provide. It not only insulates the connections but a glue also heat activated seals it from the air.

Hope this helps,

WD

 

[pwknapp]

Mine goes hot when I use the dimmer control for the dash lights. Replaced it three times and did the recall once. Now I just run with the dash lights on full.

 

[ToolManTimTaylor]

Yep the rheostat can't get rid of the heat that fast. There is a lot of load on that switch. I have run my lights at full brite ever scince I got her and have not had a hint of trouble.

 

[illflem]

From http://dodgeram.org/tech/troubleshoot/Problems.htm#electric



Headlamp switch hot - normal heat dissipation from instrument light dimmer.

If it bothers you, remove the headlight switch and punch a 5/16" hole in the top of the air duct under the dimmer wheel to cool the dimmer heatsink.

 

[Mtngoat]

Thanks for this thread and replys. I just noticed the area around my head lighht switch gets very hot when in use! Thanks!!



Robin

 

[jhurst]

Here is a link to another about punching a hole in the air duct and/or adding a small CPU fan to help cool it.



I added a fan to mine and it helps keep it cool.



Justin H

 

[fishjack1]

The recall states "3500 only" is this right?

Will they do this on the 2500?

 

[WDaniels]

fishjack1,

my dealership tells me that some of the 2500's are covered by the recall. If they were built on a date sometime in 97 they were covered. My truck missed it by a month or two. Will try to find out more if I can remember to call my friend at the dealership tomorrow.

 

[fishjack1]

WDaniels,

Mine is a '96 2500 so I am sure I am out of luck... . typical...

Thanks anyway - I appreciate it.

 

[plangone]

Thanks for all the replies.



I think my issue is a little worse than the typical "warm" switch. Mine will melt and smoke will come out of the dashboard after running the lights for more than 30 mins. Keeping the dash lights on full bright doesn't help. I think I found the culprit by removing that pink/red wire, since it was obviously the source of the heat. I am thinking whatever is on that circuit may have an issue, causing the high heat. I haven't found anything that stopped working after disconnecting that wire, which is interesting to me.



I guess I will look into doing the recall work and try to figure out where that pink/red wire goes. Guess I need to get a wiring diagram...