One spade on headlamp switch toasted...

[Bluebird]

Headlamp, (term used in shop manual) switch went out this week, (second one in 54K miles-NAPA). Had to move handle slightly in/out to make 'em work. When I went in to replace the switch I found the spade with the "H" had toasted/distorted on the plug side and spade sides#@$%!. Got 'er all back together everthing working except my warning buzzer for the 'key in the ignition' and 'headlamp swithch-on. ' What could have caused this to happen? Should I be looking for more electrical trouble down the road. Thanks in advance for the experienced responses



Patrick.

 

[cojhl2]

Without knowing all the facts my shotgun response is you are running trailer lights thru the switch causing an over load.



I run all lights not native to the vehicle thru relays, especially the trailer circuits.

 

[PBJ2500CTD]

This is a common problem with the Dodge headlamp switches if you tow or have extra loads in the lighting circuit.
The best protection is what cojhl2 said. You may also have to replace the crispy connector in the plug with a fresh new one if there has been too much damage.

 

[JLEONARD]

Patrick,

My opinion is that you are screwed... . bad.

Ship the truck to Ct and I will take care of her for you.

LOL

If you read the archives the headlamp switch is an achillees heel of the first gens. Esp if you have cab lights, etc.

There is a schematic here somewhere in the archives that shows an added relay in the circuit. Sounds like you need to add that.

Or just run silent... ... .

 

[Bluebird]

No extra lights, only a trailer hitch plug-in. If anyone has the schematic handy, please post an attachment, or pm the relay specs...



Patrick.

 

[Nic.Durrant]

I had the same problem with my lights. When i pulled a trailer my hedalight switch would get hot and would melt the plastic knob. So my friend rewired the running lights onto a different switch. So i have my head lights on one switch and my running lights on a neither. Once we did that i had no problem with my light switch since.

 

[JLight]

bluebird do yourself a favor and get updated switch and tow light harness from dealer. search the threads cause the part numbers are on here. problem is the wiring harness is not heavy enough for the added load of trailer lights. i did mine and gremlins all gone!!!!!

 

[JLight]

did some research CAJM8190 switch upgrade www.dodgeram.info/tsb/relay/819.htm there is a trailer towing harness for your truck too. cant find the number. got that through dealer too. i think it was 230. 00 for everything. cheaper than a new truck!

 

[tugboatphil]

Patrick, here's a pretty good thread to read. I finally realized I could bookmark a thread and label it so I'd remember what it was later on.

There's a bunch of diagrams and pictures for wiring relays. You do have to sort through Jimmy, Cow Tipper and Petey's hijinx to figure out what's real and what's not.

Have I done any of this? No, I just stopped driving after dark...

https://www.turbodieselregister.com...-ram-forum-1989-1993/196594-left-dark-9.html?

 

[PToombs]

That reminds me, where the heck are my proteges?



Sorry Tugger, sometimes I get carried away.

 

[WyattEarp]

i am on my third switch myself, it melts the inside of the headlight switch, there is one wire that gets extremely hot!! and i do not have any other lights except what came on the truck and don't pull a trailer either.

I found the relay diagram and printed it out some time back, but when i went to look at fixing and making a larger ground wire and fixing relays i could not figure out how to do it with the factory connectors in their plastic housing???

Any ideas? i believe the wire that gets really hot is *H* green maybe can't remember, the truck is still at a body shop since my accident in early Feb.

 

[JGrefenstette]

hahhaha. Phil at first i was gonna give your a hard time for callin out pete, matt, an me like that, but i just looked at that thread for the first time since a year or so, hahhah dang. yeah if you can sift through all the verbal diaria there is actually some really good and helpfull info in that thread. the visuals are great.

 

[JGrefenstette]

oh, by the way, my switch is still working fine. occasionally it will go out, an i just bump it once an they come back. but its never melted down, i think it will continue to last as long as i need it too since those relays have isolated the switch from the load. man if i had done that project after i took electrical class at diesel school it would have never been so difficult to wrap my mind around. man that electrical class was intense, my teacher at diesel school is a writer on the ASE testing team, he is certified in everthing imagionable, one of the smartest men i have ever met. such a privalage to learn from him. if i told him i fixed something on my truck, he wanted to know why the part failed, how i fixed it, and how my fix will prevent the same issue from happening again. guy is brilliant.