lthughes

Hello, This is my first post so I dont know all the abbreviations that ya'll are probably used to. Approx 2 weeks ago I was driving home and my high beams went out. Not what I was expecting at 10 pm on a back country rd. flip the high beams off and low beams worked. Got home and turned high beams on, they worked for a few min then went off again. flip to low and nothing happened. Thought headlight switch went out. To O'reilly and bought one 19.00 installation was easy and lights worked. Problem solved (WRONG) had same problem again except low beams cont. to work. called O'reillys and they said dimmer switch. So $58.00 later dimmer is changed out. still having problems. Viewed some post here today and saw some stuff about dodge having wiring issues. took dash off and looked at plug at headlight switch. one spot on wiring harness looks melted but wire looks o.k. to me. What should I try next? any ideas? how easy to replace wiring harness for headlight switch? Thanks.

1998 Dodge 2500 Quad cab, 150k all stock, rebuilt trans 99638 4/15/2005.

ironbutt

I had the same problem with my 02, I localized mine to the switch in the steering column. I used elecrical contact cleaner spray on the switch in the steering column. BUT first you must disconect the batterys, and bleed off any electric. to protect against any chance of shorting out anything electric, and /or tripping the air bag.

lthughes

Ironbutt, Thanks for info but I already have installed a new switch in the steering column. Took my dash apart again last night and found where headlight switch is connected to wiring harness in dash, It looks like the plastic around one of the pins has been hot enough to melt. It looks like the pin was lettered as "H". Ican only assume that means Highbeam. I could be wrong. Any help in the matter is greatly appreciated.

smokeyram

i doubt you have the same issue i had, but ill share it anyways. after similiar symptoms, and doing the exact same game of throwing parts on it, still no luck.
i had my whole dash apart on sunday, and then thought about my plow wiring harness. you being in texas, i doubt you have a plow.
anyways, i unplugged the harness, put the bulbs back into the factory plugs and viola. lights work like new, and a new switch and multifunction switch in the process.

lthughes

Am just concerned with the partly melted connection at headlight switch in dash. Is there a replacement wiring harness that just goes to headlight switch? Wire that comes off pin "H" looks alittle drawn up like it has had some heat distortion. suppose to go camping this weekend, not going to happen as driving at night and hooking up 5th wheel might over-do switch and I dont want to end up on the side of the road.

infidel

Don't think your '98 was covered under recall but there is a switch recall kit the dealer sells that includes the connector with short wires that you can splice in.

Here's the recall info http://dodgeram.info/tsb/recalls/819.htm

smokeyram

you can also get rid of the plug, and use connectors. takes some time, and have to pay attention when switching the switch out, but ive had 2 of the harness side connectors melt up, so i got rid of it.

lthughes

Is it smart to only replace the terminal that shows signs of heat damage? Also you can only see about 6 inches of wire with switch pulled out. Should I replace the light green wire that goes to pin "H" as far as I can safely do it? If so with what gauge wire? Thanks for all ya'lls help.

wyododge

Once you get all of your wires fixed, you should do a relay kit for your lights to take the voltage out of your headlight switch. You can read up on it here.

I did it and it made a huge difference, My headlight switch does not even get warm anymore. PM if you want more details, or do a search for headlight relays.

Steve Roseman

That is some interesting reading. When you did this did you notice an improvement with the headlights?

wyododge

BIG TIME!!!!

Night and day. Or should I say night to day!!! It was a fairly cheep mod and by far made the biggest difference in everyday driving. The only thing I would do different, is to go ahead and spend a little extra for the OEM headlights. D Stern warned me but I did not listen He was right!!!

BTW here is a wiring diagram for a negatively switched system, which I believe you have. Had to redo mine after I found that little gem!!!!

Steve Roseman

Mine is the positive switched system.
When you mean OEM headlights do you mean the sport headlights?

blackimpala

I did the relay thing on my truck years ago. Found it on: http://www.madelectrical.com/electrical-tech.shtml

Also my 60 Impala has relays. It does make them brighter and takes the load off the switch.

wyododge

The positive switched system is VERY easy to wire as I'm sure you already know. The negative one is kind of a bugger!!!!

both actually, get OEM sport headlights. From dodge or napa or some other parts house. They have the same mounting and adjustment system system but sport headlights have two bulbs per side. They bolt right in. I believe you also get new turn signal lights as well, kind of a package thing. For some reason, dodge went with the single bulb system on non-sport models which are completely worthless. If you have the non sports, and do the relay thingy and change out to sport OEM you will be amazed!!!!

Daniel also have a good daytime running light system. You can read about it on his sight as well. I have not done that yet, but I assure you that the components are top notch!!

After you change them out do a search for headlight adjustment. There are some measurements you need to ensure your headlights are pointing as they were designed by the factory engineers for optimum lighting. If you can't find it let me know and I will hunt it down. I know it is in here somewhere.

lthughes

Well, Last night I tried to get the melted connector out of the harness at the light switch. Not Happening. The plastic harness is melted to the connector. Any and all ideas will be greatly appreciated.