2nd Gen Non-Engine/Transmission Very Hot Light Switch Problem

[pfmoale]

This is my first post, please advise if I have done something wrong.



My truck: 2001 2500 auto trans. 4X4, LB Ext. Cab. I have the “fog” lights option.



I just installed a Banks Power Pack unit on my truck. I ordered two extra gages, along with the two that came with the package.

The engine oil temp and auto trans temp gage. In wiring the gauge lights,(4 total), I removed the headlamp switch and located the wire that controls the dimmer. I wanted the gauge lights to be on the same dimmer as the instrument panel lights.

Here is my problem:



When I turn on the headlight switch, after about 20 plus or so minutes, the panel right around the dimmer switch gets EXTREAMLY HOT!

How can I reduce the heat problem at the dimmer/rheostat/pot? I want to keep the Banks gauge lights on the same dimmer/rheostat/pot as the rest of the instrument lights.



I called Banks with this problem and they said it could be a bad ground.

The area where I put the ground was scraped clean before attaching the ground lug. What can I do to reduce the extreame heat around the dimmer wheel?

 

[24V-DSL]

My panel gets very hot also unless I keep the dimmer switch on full bright.

 

[ToolManTimTaylor]

Hey Pete,



This has allways been a problem for the headlight switches in general. There has been many an atempt to correct this and one of the easiest and most widly used methods is to drill a couple 1/8th inch holes in the Ductwork that feeds the vent right next to wthe switch so that airflow will help keep switch temps down. Another thing to do is to keep the panel lights at full brightness when the lights are on. It's nothing the Banks kits has done it just is what D/C gave us to work with but you are just noticing it now believe it or not. Try a search on headlight switch hot and see what comes up.

 

[Matt42]

I first encountered the heat phenomenon with the headlight switch on a 1961 Rambler. I thought something was wrong with it, but it was normal. Newer cars have seemed to have even hotter switches.

 

[RSarvie]

Exact same deal here!

Just did my gauges last week and noticed it on the first test drive right at the dimmer. I tapped a line right from the #5 fuse. Anybody have any failures from it, or do they stay together, just warm? Thought maybe when I put in my "Add a Circuit" it would fix it, but doesn't look like it.



Kind of OT, I'm having a heck of a time finding "Add a Circuits" for ATM fuses. Can order them from Auto Value for $20... OUCH!!! Found the ATO (standard size) add a circuits for $8 at Fleet Farm! No ATM size and the kid there said they won't order any??? Anybody any tips???

 

[ToolManTimTaylor]

Simple "Hot Headlight Switch" Search brought up:



Fixes are in theese threads



Melted switch



Hot Dial



Up in smoke



Up in smoke again



What is everyone doing about Junk switches?

 

[jhurst]

You can also add a small fan used on computer cpu to help move air over the switch. I have one on mine. Seems to help. You can here the fan when the truck isnt running, but it the truck isnt running, I dont need the lights on!



Some holes in the air duct is a good idea.



Justin H