Headlight switch.....

[HoleshotHolset]

My lovely little headlight switch decided to arc out and weld itself in the on position today. The switch has been operating erratically... . no headlights every now and then (twice in two weeks... ). So today I noticed a little bit of a smell and knew where it was coming from..... I put my hand on the headlight switch and it was H O T !!!

So..... I took apart my dash... disconnected the switch and went into a place where 100Billion people have been served and ordered my breakfast... . came back out and drove home disappointed in my truck.

The wires are a bit crispy and the connector where it goes into the switch is a bit well done also.

So, I guess I'll be getting in contact with my friendly DC dealer or some other DC parts place for a new switch and connector.



Check your headlight switch..... if it messes up even a little... it's on its way out and may cause a fire!



Matt

 

[Extreme1]

You're in Luck!!

Maybe.



There is a recall on this very item, it includes a few inches of wiring harness.



While its in for that, have them do the headlight switch relay and any other stuff it hasen't had.



I had mine die in January at night. I had headlights only - no running lights.

 

[HoleshotHolset]

Hrmmmmm... . I'm not the original owner of this truck, but I've had it since May...

I'd love to let DC pay for this one... obviously it's a bad design... . but it does have a lot of miles/use on it.

Maybe they'd like to do my throtte cable too...



Matt

 

[Great White]

Hot Headlamp Switch

I found that my headlamp switch was so hot you would burn your finger on the dimmer adjustment wheel. I brought this to the service department for repair. They said they checked the draw on the circuit and "everything was normal". I say bull still gets hotter than I belive it should. If the dashlamps stay at full brilliance the switch remains cool, so I tend not to dim the dash..... I will continue to think of a suitable BOMB.

Rich

 

[LMontyCJ2a]

Nice timing on this subject.

I was just going to ask if anyone else had this hot dimmer switch problem.

 

[Great White]

Actually this is a old topic. DC has chosen to ignore the problem.

Rich

 

[BCFAST]

I know that our Rams all have a bad switch, but I was under the impression that it was because of overloading the switch with a bunch of trailer lights. I had my trailer lights wired thru a separate toggle. Now I have something else to worry about? Maybe the Ford guys are right about Dodge.

 

[Extreme1]

There are a couple things going on here!

The recall applies to the older 2nd gen body style trucks. '94&'95 for sure, not sure about others.



The headlight switch overheats for 2 reasons on the older 2nd gen's.



1) The switch and wiring are not up to the task. This will cause the melt down (mine had smoke rolling out of the dash).



2) The trailer (and running lights on 3500) circuit is too much load. (This one might affect newer trucks too. )



There are 2 recalls - 1 for the switch and wiring and one to add a relay.



Yes they will fix the throttle cable too (just got that in the mail last week). When at the dealer, they can check to see what recalls have been done. 4x4? You need the front spring perch brace recall done too. Sounds like the previous owner didn't get it serviced at a Dodge dealership. Congratulations! The value probably just increased!

 

[HoleshotHolset]

I'm hoping that DC will like working on my vehicle for free... . sounds as if they will be busy!

SUPPOSEDLY the previous owner had it serviced at DC... . I'm beginning to wonder... ... ... .

I got a good deal on the truck, though... . I paid a LOT less than book... . but then again, I'm dealing with little stuff like this that accounts for the markdown in price.



Thanks for the info!

Matt

 

[Slick]

My buddy has a 95 3500 and had the headlight switch problem. I believe it was finally taken care of by DC. But I too have noticed that the dimmer on my 01. 5 stays very warm. Well I guess it might be another recall coming up!!!

 

[HoleshotHolset]

Keep in mind that what burned on this switch was not the dimmer at all. It was the actual internals of the switch that turned the headlights on/off and had (from the looks of it... ) very little to do with the dimmer... ... the switch has a hole burned right through it where the OE connector connects to the switch... you can actually see the internals of the switch.



Matt

 

[Slick]

Info only: On my 01. 5 the dimmer,dome,cargo and bright light (when its raining during the day you can go to the bright position and it makes all the dash lights, radio etc. come on bright without the interior lights coming on)is totally seperate from the headlight, park and fogs. Don't know how far back that set up goes but the dimmer stays pretty darn warm. I have no accessories or additional lighting hooked up to either switch. Any others with this set up besides Great White and myself having these symptoms?

 

[Don M]

I got DC to replace my headlight switch and re-emburse me for the three others I threw at it over the years. They did some relay crap and added other small harness.

Took a few minutes and so far... . all is well



It is a recall for some trucks. After much complaining from the public the Government made 'em do it.



Don~

 

[Dave Fritz]

Recall 819 covers headlight problems on 1994-1997 3500 Rams.



Customer Satisfaction Notice #820 contains wiring recommendations for 1500 and 2500 Rams with accessory lights or trailers.



FWIW, the headlight switch on my 94 2500 died about a year ago. I replaced it for $15 at the junkyard and then installed a relay to power the tail lights and running lights at the rear of the truck. The headlamp switch doesn't even get warm now, and the tail lights are much brighter.



Dave

 

[HoleshotHolset]

Okay, I'm thinking that I have to arrange a setup similar to what Dave has... only I'm going to have a separate relay for the headlights and the taillights. Hopefully I will be able to find a suitable relay that is capable of sustained use at a reasonably high load..... and keep spares on hand at all times, of course!



Thanks a million!

Matt

P. S. Supposedly the previous owner took the truck for the headlight recall... . that's what the folks at my local dealer said. They said I have 3 more recalls, though... . throttle cable, hood latch, and the spring tower brace deal.

I have to buy the parts for the burnt up switch... . I'm hoping this is the last time I will have to do it.

 

[HoleshotHolset]

Safety Recall No. 819

Okay, it seems as if the headlight fiasco is over with.

I did the switch from the DC (part # CAJM8190) Safety Recall No. 819. It comes with a new and improved switch, ALL of the wires that go to the headlight switch - with connectors and good heat shrink tubing, a neato 'overlay relay harness' that reduces the load on the switch, and a new connector that melted in the original mishap. I borrowed the DC safety recall manual and made a few copies of key pages... . all went really smoothly.

Word to the wise, you may as well buy this as the switch alone is $20+ from DC. List on the recall kit is $45... I paid $27. 50.

This recall applies to '94-'97 3500 series trucks only... . DC says that the 2500's don't have a problem... . bologna! So, if you love your truck and hate electrical fires, do the recall kit.

If anyone has questions, you know how to talk to me.

Thanks to the members of TDR, my truck is a little safer now!



Matt

 

[tgbol]

My headlight switch dimmer was getting so hot that I could barely touch it. One day when I was working on the radion I realized that the A/C vent was directly below the switch. I punched 2 1/4" holes in the top of the duct. Just got back from a trip where I drove 8 hours at night across the desert- dash lights dimmed low. Switch got warm but nowhere as hot as before. The heat sink on the switch is in dead air. The holes in the vent tube allow a little circulation allowing the heat sink to work.

 

[HoleshotHolset]

I was thinking of doing exactly this when I had my dash all apart... you could also use the 'demister' tube that runs right alongside the dimmer/headlight switch. Since not too many people point hot air directly at themselves (most opt for heavy foot area warmth) in the winter months, this might help out a lot in all seasons.

It's never too late to do this mod... . my stock radio is horrible and that's due for a bomb soon.....



Matt

 

[Extreme1]

When I bought the kit it was $90 wholesale!!!



I better get reimbursed!

 

[HoleshotHolset]

WHOA!! That's double the list price I paid for my kit... . If you need any DC stuff, maybe I can get it cheaper... it's worth a shot...



Matt