Attention: TDR Forum Junkies My five month old headlight switch started to smoke on Thursday along with intermitent clearance light/IP light operation. Actually it turned out to be the wiring harness connector plastic getting hot. The two female spade connectors that service that circuit evidently corroded slightly and, because of the high current through the circuit, got very hot.
I was going to replace the headlight switch and plastic connector only (it is available from Dodge) but Fullerton Dodge had a "kit" to really fix the problem. It is p/n 4886449-AB (list $76. 50) and includes: A new headlight switch, the entire connector with wires pre-installed and shrink tubing.
The different thing is the female spade connectors and switch male connectors are chrome plated instead of just plain copper. This should help keep corrosion down so that no high resistance, with corresponding heat, causes problems.
You cut the old connector off and solder the "pigail" to the old wiring. The wire for the clearance light circuit is 14 GA on the new connector vs. 18 GA in the original.
It appears the connectors can be just as much at fault as the switch itself for the clearance light circuit problems.
The switch supplied in the kit is p/n 56021892 which is different from the stock 56021898.
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'93 W350 Club Cab, Bright White, 5 sp. , 132K, Factory Options: LE, 4. 10 Limited Slip, 7600 lb. rear springs, tachometer, front stabilizer bar. Mods: Banks stinger plus, Linex bedliner, 25,000 lb gooseneck ball, 10,000 lb receiver, Tekonsha brake controller, POWER WAGON injectors-WAY faster than stock!.
I was going to replace the headlight switch and plastic connector only (it is available from Dodge) but Fullerton Dodge had a "kit" to really fix the problem. It is p/n 4886449-AB (list $76. 50) and includes: A new headlight switch, the entire connector with wires pre-installed and shrink tubing.
The different thing is the female spade connectors and switch male connectors are chrome plated instead of just plain copper. This should help keep corrosion down so that no high resistance, with corresponding heat, causes problems.
You cut the old connector off and solder the "pigail" to the old wiring. The wire for the clearance light circuit is 14 GA on the new connector vs. 18 GA in the original.
It appears the connectors can be just as much at fault as the switch itself for the clearance light circuit problems.
The switch supplied in the kit is p/n 56021892 which is different from the stock 56021898.
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'93 W350 Club Cab, Bright White, 5 sp. , 132K, Factory Options: LE, 4. 10 Limited Slip, 7600 lb. rear springs, tachometer, front stabilizer bar. Mods: Banks stinger plus, Linex bedliner, 25,000 lb gooseneck ball, 10,000 lb receiver, Tekonsha brake controller, POWER WAGON injectors-WAY faster than stock!.
