1995 Ram 2500

So I've been having problems every once and a while with my headlights not coming on. Push the switch back in and pull it back out again and the lights go on. Took the switch out today and one of the terminals (H) was black and slightly loose, which I believe is the terminal for the headlight. The harness where that terminal plugged into was also dark and all the plastic around it was melted. In fact, there was actually a small hole in the outside wall of the harness.

I ordered a new switch and harness, as well as some posi-twist connectors, which can be used for auto wiring, but my concern is that I would like to know why this happened in order to prevent it from happening again or even worse, a fire. Research showed me that this has been a normal occurrence with older dodges.

Is there anything I should look into, as I want to make sure there is nothing out of the ordinary that would be causing the harness and switch to fry.

 

Short answer: Buy a HD headlight harness from LMC that uses relays

Long answer: in these years the switch activates the power so you have a high voltage going through it which the wires and plastic can't handle. In 02 (1500) or 03 (2500/3500) they switch to switching the ground for the headlights which is safer

 

Thank you for your comment and that makes sense. I did contact LMC just now and all they had was the standard switch and harness. They said they couldn't help me with a HD harness that uses relays unless I gave them a part number.

Did you go this route and if so, do you have a part number I can give them?

 

My hasn't went out yet so no I haven't went that route. There are numerous suppliers. LMC is good and Daniel Stern makes them (I don't know anything about him though). Just Google "2nd gen Ram relay headlight harness" find one you like and look at the reviews. You could make one yourself to.

 

Here it is.

 

Yes, got it, thank you!

I gave them a call to see if I can get a copy of the install instructions to make sure this is something I could do, but none was available. They did read to me over the phone what one of the techs stated to someone else who inquired about this, but she didn't mentioned, that I heard, how this hooks up to the switch to turn the lights on. She did mention the wiring replaced that which went to the headlamps, a ground, relays and that it connected to the battery, but nothing about the switch. I may have to call again to verify that.

Now, even though this harness ads power from the battery, there is still power going through the switch, as there didn't seem to be any disconnection made. Would that still present a problem or wince there is no headlamp draw, it should be fine?

In any case, did you (HeyYou) install this harness and if so, what info was missing in what they told me, in reference to switch connection?

Thank you for all your help ...

 

Once you install the harness with the relays, the head light switch just operates the relays. They don't require much power so your switch won't melt again. The power goes from the battery, through a fuse, then the relays to the headlights.

 

It's not only the headlights it's the running lights also. Both circuits can melt the switch/connector. There was a recall for the 3500 but the 2500's have basically the same problem. The 2500 pull a bit less amperage then the 3500 but it's still a problem.

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

If you replace the switch/connector you should be ok for a # of years but it may come back(running light circuit) . You can replace all/most of the running light bulbs with LED ones(non resistor) and that will drop the amp draw down enough it won't be a problem.

 

Thank you everyone for your input and advice on installing the relay harness kit, as well as changing out the bulbs, which will be my next steps. I've just competed installing the new harness and switch and all is working now. Here are photos of what I took out. Looks like the switch may have been the original. The burnt parts of the harness and burnt terminal are letter "H", which is for the headlamp.



Here is where the side of the harness melted out.



You can see towards the right, one of the terminals is burnt.



Looks like an original part.



The plastic on the harness is melted around the clip.

 

imho if someone else has headlight switch start doing this, don't dick around and wait before replacing it... mine acted funny for a week or so then suddenly started smoking and literally lit on fire while were driving through an ice storm 700 miles from home...