Hi guys,
I have a 96 ram 2500 with the roof lights, fog lights. I have burned through 2 wiring harnesses on the headlight switch. I just replaced the switch and the harness after my dash lights and front / rear running lights went out after the harness melted again. I assumed they overloaded the switch with the fog lights and the roof tear drop lights. I found that this is a common issue for these years of trucks but the only official recall was on the 3500. So in the past after I replaced the harness the lights have worked fine for a couple years before it melted. Now that I know about the recall I would like to find out where I can buy the relay kit for the headlights so I can stop burning my pig tail. Second problem is my new pigtail and switch turn the lights on but randomly keep blowing the 15amp fuse. I cut out all the burned wire when I swapped out the pig tails, what would be causing my fuse to pop randomly like this?

 

Check out LMC truck for their headlight harness. I've heard though sometimes it's not long enough so people have to modify it. And it's made in Japan or some foreign place. Check out Daniel Stern Lighting. He custom makes the harness and is made in the USA. I haven't bought one from him, but I plan to. Shoot him an email.

 

I do not see one on LMC, I can google search and all that comes up is the setup for around the 89-95 years, mine is a 96. If any one can find one and link it, or the instructions to fabricate one it would help me out greatly. Im also still confused as to why the past 2 times when I have replaced the melted pigtail and switch the lights have worked fine for years, but now after replacing them I am popping fuses randomly. Any thoughts?

 

There is DIY in the faq section, but, the wiring diagram seems to have gone MIA. (it's on the last page.) Have a look, see what you can make out of it.

 

The recall should have included the 2500's! There is only 4 more marker lights on the 3500's over the 2500. Still to much of an amp draw. I wonder if the recall harness is still available from the dealer?

http://dodgeram.info/tsb/recalls/819.htm

 

As far as I could find they only recalled the 3500's, and posted a warning for the 1500 and 2500. As far as the 4 more marker lights on the 3500, where are the extra lights on those trucks?

I did see the DIY thread but the diagram is missing so I was hoping there was another link somewhere.

 

Extra lights were in the fender flares. (front and back of them.)

Might PM the author, and see if he can put it back up. The idea is, you want the headlight switch to control the relays. Let the relays supply power to the headlights. Bear in mind, the headlight switch normally controls the ground path.