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Out of ideas: electrical issues

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Old Apr 1, 2022 | 01:02 PM
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Default Out of ideas: electrical issues

1996 Dodge Ram 2500 5.9 360 gasser. 4x4.
To start out, my headlights, blinkers, hazards, brake lights do not work. I’ve replaced fuses and relays, all the switches(brake light switch, headlight switch, and windshield wiper module)
No success. My running lights do work. I have the mechanic Manual and have been chasing wires and I’m getting power to all the right places. Other than going through and replacing all the wiring or bypassing everything and make my own circuit, I am out of ideas. Anybody have advice?
 
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Old Apr 1, 2022 | 01:57 PM
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Are you getting power at the sockets? How about ground? The headlights are switched ground not power. So they will have constant power. How about power at the hazard flasher relay in the fuse box in the interior? Here is what I would do.
HEADLIGHTS:
Turn headlight on at the switch. Go out at one socket and check for power and ground, you have to be missing one. Then split the harness and check for what you are missing (power or ground). Then check the other side.
HAZARDS:
Check for power at the flasher in the interior fuse box. If you are getting power then I would go to the rear socket (easier then the front) and check for power. If your running lights are working that is telling me the ground is good and you are missing power. A common place for the wires to break is under the truck where the trailer plug meets the main harness.
 
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Old Apr 1, 2022 | 03:15 PM
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Actually '96 is still the old design that had the melting headlight switch feature IIRC the change to ground switched head lights happened in '98.

You need a test light or a voltmeter. Then work along the wiring harness from the battery on. Fuse 6 in the PDC, red/green wire to headlight switch, light green wire to multifunction switch, red orange is high beam output, violet/white low beam output.
 
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Old Apr 1, 2022 | 04:38 PM
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Originally Posted by DerTruck
Actually '96 is still the old design that had the melting headlight switch feature IIRC the change to ground switched head lights happened in '98.

You need a test light or a voltmeter. Then work along the wiring harness from the battery on. Fuse 6 in the PDC, red/green wire to headlight switch, light green wire to multifunction switch, red orange is high beam output, violet/white low beam output.
I thought it said 98 but yes you would be correct
 
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Old Apr 1, 2022 | 06:37 PM
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Thanks for the replies! I will definitely test them out. Would the melting switch cause issues to all the problems I listed or just the headlights?
 
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Old Apr 1, 2022 | 07:04 PM
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Originally Posted by Smokedup
Thanks for the replies! I will definitely test them out. Would the melting switch cause issues to all the problems I listed or just the headlights?
I believe it would be just the headlights and park lights
 
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Old Apr 2, 2022 | 06:28 AM
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my headlights, blinkers, hazards, brake lights do not work.
The headlight switch only works the running ,fog and headlights. The multi purpose switch is another trouble spot, Need to check that.
 
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Old Apr 2, 2022 | 07:29 AM
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Originally Posted by Smokedup
1996 Dodge Ram 2500 5.9 360 gasser. 4x4.
To start out, my headlights, blinkers, hazards, brake lights do not work. I’ve replaced fuses and relays, all the switches(brake light switch, headlight switch, and windshield wiper module)
No success. My running lights do work. I have the mechanic Manual and have been chasing wires and I’m getting power to all the right places. Other than going through and replacing all the wiring or bypassing everything and make my own circuit, I am out of ideas. Anybody have advice?
sHI there should be an authorized dealer or mechanic workshop around you, why not get help from them and get a quick fix
 
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Old Apr 3, 2022 | 12:21 PM
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I'm not sure what you mean by mechanic manual, if it's a Haynes or something like that recommend you download factory service manual available under 2nd gen Ram tech. FAQ,DIY. In those manuals there is brief descriptions on how each of the circuits operate along with wiring diagrams. I agree with Der Truck that the fuse 6 circuit needs to be looked at, from the diagrams that is all I see that serves headlights, brake lights, blinkers, and hazards. There is some differences in some of the diagrams, not sure what that's about. A voltmeter is better than a test light. May have to load the circuit as in turn the lights on while testing to find the problem.For example a faulty connection before the light switch will show proper voltage at the switch unloaded but lose voltage to the switch when loaded.

By the way big thank you to the person that made these manuals available for download, has been a big help to me in working on my '97.
 
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Old Apr 4, 2022 | 10:32 AM
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Ok after going through diagrams and my truck I’ve found I’m missing the 20BK wire coming from positive terminal on the battery that goes to splice 148. Now there aren’t any diagrams for that splice. Anybody have pics or info on splice 148?
 
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