I have a 1995 Dodge ram 2500 and my headlight switch has a pen that is melting at the connector heard that there was a relay upgrade that fixes this issue, but cannot find any information on how to do it. I use this truck to haul my horses so I need to get this fixed if someone could help that would be greatly appreciated.

 

Sounds like you will need to replace your headlight switch and the connector/harness behind it, as the headlight switch and harness tend to burn up over time, since so much current flows through the switch and wiring.

Once the switch and wiring are replaced, you should certainly consider using a relayed setup for your headlights. You can purchase them through LMC Truck, Amazon, eBay and other outlets. If you feel (as I did) that the light output is insufficient, you can upgrade to the 4 bulb sport style headlights which will greatly improve headlight brightness and will require a relayed harness to support the added current used by the sport headlight setup. I use a relayed harness from these folks for my sport headlight setup - https://ceautoelectricsupply.com/pro...2-dodge-truck/

 

Most likly is your BCM shoring out .its behind the driver kick panel.when it starts to fail all kinda crazey stuff starts to happen

 

A 1995 doesn't have BCM!
There was a recall on the 3500's for this issue but it should have also covered the other trucks. The 2500 and 3500's have more bulbs(running lights) than the 1500's and puts more load on the switch. The relay kit will remove the load for the headlights but won't do anything for the running lights. Both melt the switch(especially if you use a trailer). You can get led lights(without a resistor!) for the running lights that will cut the amount of load on the switch. You can relay kit for the headlights from LMC and a few other places.

 

The switch and connector where replaced but it is heating up and starting to melt again I want to add a relay setup that I was told I could make but I can’t find blueprints for it. Sorry it took me so long to get back on here wife broke her foot. All I need is how to make it.

 

LMC Truck, and Geno's garage both offer plug and play versions of the relay harness. Prices are reasonable as well. I think the Geno's version is a bit heavier duty.

 

I used this kit on my 96 https://www.ebay.com/itm/133129053506

 

That's only for the headlights. You can wire in a relay and use the switch to trigger the relay for the running lights.
https://www.boogeylights.com/heavy-d...FopkHlpcKAXRaL

 

Just to say, headlight switches are how most of these burn down so don't leave it with battery connected and keep tools with you and ready to disconnect if driving.