light switch problem?

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When the headlights are on, the area around the headlight switch and dimmer knob gets very hot to the touch on my truck... I just noticed this phenomenon. The truck has 4400 miles on it. Has anyone else noticed this on other trucks?

 

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What year is your truck? I know for my 1996, Dodge had a recall on it to replace the switch since it could possibly overheat and cause a fire if left on for an "extended time", whatever that meant.

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1996 3500 Clubcab SLT, auto, 4. 10 limited-slip, TST #5, K&N, Dunrite converter, Trans-Go shift kit, Straight pipe, DiPricol EGT, boost & trans temp. gauges, 9 ft. aluminum flatbed and tool boxes with Venco dump. Custom front bumper, Hadley air horn.

 

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It's a 2001. The heat in the switch feels excessive, to the point that I'm reluctant to turn on the lights now after driving home from a trip last night. I guess that means that this phenomenon isn't normal!

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2001 2500 ST qc 4wd longbox 6 spd ETH; driftwood,stock

 

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The headlight switch on my '98 just melted last week. I was in Boston at the time around 1:00 a. m. installing some new servers. Came out of the data center and the lights wouldn't work. I live in New Hampshire. I was not pleased.

Luckily the headlights worked and I drove an hour to home with the flashers going.

Taking the dash apart the next day (great. . the dealer lost the screw holding the dash on when the switch was last replaced) I found the electrical connector on the switch had melted. It looks like the lead for the running lights is overloaded. Off to the dealer for a new switch ($22--great!) and a new connector ($66--ouch!). The new leads have a different color code and wires that were of smaller gauge are now larger and larger gauge wires are now smaller. Strange.

Anyway the new switch works. This seems to be a common problem on 3500 trucks. I suspect the wiring isn't up to the task of supplying enough current for the extra running lights on a 3500 and slowly overheats with use. I just drove cross-country three or four times in the last few months so I guess that'd qualify as "extended usage".

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'98 B5. 9 5spd 4x4 Quad Cab 3500, 3. 54, Banks PowerPack, PacBrake, 60-gallon Aero fuel tank, Bilstein shocks, Firestone air bags, Reese 20K fifth-wheel hitch, Icom 2m ham radio

 

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I decideded to take my switch apart on my '00 and I found out this is not a good idea, because I screwed it up. (Don't ask why, my wife has asked me why 100 times and I still haven't come up with a good reason). But since stupid me messed it up then stupid me will fix ir. Called the local dealer and he has plenty of them in stock with or without fog and cargo lights. Seems odd since they usualy have to order such low maintenance parts for such a new truck!!!

[This message has been edited by Kerry (edited 07-02-2000). ]

[This message has been edited by Kerry (edited 07-02-2000). ]

 

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This is a common problem on the 3500 trucks, the repair for the DC people involves replacing a wire harness and it is larger gage wire. I have this problem on the truck they are buying back and they will not repair it until it completely fails. Get the dealer to call the hotline and fix the problem before it causes a fire under the dash.

 

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The light switch gets hot 'cause there's a big honkin' heat sink mounted on ths switch assembly. For non-electronic types, these are a chunk of finned aluminum to dissipate heat for electronic chips that run hot. If not for a heatsink they would quickly go into meltdown. I think the heat shink is for the dimmer rheostat, not sure though.

I also noticed my CD player is a CD heater #ad

Maybe I'll start a thread about that. . . CD come out HOT after playing it through #ad


Vaughn

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2001 Ram 2500 QC SWB 2wd, Patriot Blue/Driftwood, HO Cummins & 6-speed, 3. 54LSD, Cab & Fog lamps, Camper & Tow Pkg.
BOMBings: K&N RE0880, straight piped, debadged body, AutoMeter Sport Comp Boost & Pyro gauges, Amber turn signal conversion
Performance: 245rwHP on BD Dyno, 0-60@ 11. 5 sec 17/22 mpg city/hiway
8990 miles (6/26/00)

 

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That makes sense, as most of the heat seems to be coming from the vicinity of the dimmer switch reostat. It seems too hot to me, but it sounds as if a fair amount of heat is to be expected.