Been all over google. Got a 96 ram 1500 with clearance lights. Got the whole headlight switch melt going on. Lmc has a harness but it’s pricey to get to Canada and I’m doing a whole lot of other stuff so wanna save some money. Just want to know a simple way to get theses lights safe and working properly again. Got a new switch and pig tail but haven’t put it in yet cuz I wanna address the real issue before I fry the new parts.
so.
if I tap into the headlight hot wire with a relay for each light and an in-line fuse for each then I’m good? Saw this one guy said tap into the negative wire? Bit confused.
thanks for the help

 

The easiest (not most elegant) way would be two relays driven off the red/orange (high beam) and violet/white (low beam) wires. Power to the relays from the battery with a 40A in-line fuse. New wiring from the relay to the headlights.

 

awesome! Thanks man!
what gauge wire should I use? And just spade connect to the headlight switch then eh

 

I had a meltdown too and after replacing the switch I also installed the relay from LMC and yes, it is pricey. But I can tell you that what I noticed is, even with the relay installed, the dash on top of where the switch is got warm. I found out that since it's a dimmer switch, if I have my dash lights on full at might instead of dimmed, the switch doesn't get hot, so you may not need to install the relay, just don't dim your dash lights at might. That may save you from another burned out switch, which has been a problem with these trucks.

 

I converted my truck to sport style headlights so I could see better at night (4 headlight bulbs with sport headlights vs. 2 headlight bulbs for the stock headlights). To get the most out of the new headlights and not melt my headlight switch, I purchased a relay/fused style harness from these folks - https://ceautoelectricsupply.com/hea...ion-relay-kit/

While pricey, the harness is very well made and was very easy to install. In addition, the headlights are now really bright and I can see much better while driving at night.

 

LMC isn’t sounding so pricey now bah!

 

18g is fine, realistically the headlamps pull less than 15A together in normal operation. You can use the wires close to one of the headlights as control for the relays, no need to do anything inside. You need to cut them anyways.

 

There was recall for the 3500's but as you found out it effects the other trucks also. Problem is the amount of amps running threw the headlight switch. Over time it heat's up and melts, You can install a relay for the headlights but you still have the same amount of amps running threw the switch for the driving lights(there are two terminals,one headlights one driving lights). Putting relays on both is the way to solve the issue. You also can change to led lights witch will cut down the amp load threw the switch.