I bought the truck July of last year,in Sept. it cooked the light switch which was a Dodge part.
When it went the plug that it goes into got REAL hot and melted in a couple of spots but the wires were OK so I just pluged the new factory switch in.Worked fine.Today I fired it up to go to work,pulled the switch,no headlights but everything else.I kept playing with it and had headlights for a few seconds but that was it,still had everything else.I wired a seperate switch for the trailer lights so it wasn't overloaded from that but something is heating it up.Anybody have the same problem?Any ideas?

 

Yup, me too. Welcome to the wonderful world of Mopar!

I put in 2 heavy duty push-pull switches. One take the place of the headlight switch, the other the parking lights. I replaced the stock switch 3 times before I changed to the 2 switch system. The stock switches aren't heavy enough, (apparently), and the terminals that connect to the back of them tend to loosen up, creating a bad connection, thus heat. Since installing the 2 switch system, I haven't had any problems, altho I WILL say the one I use for the headlights still gets pretty warm to the touch.

Good luck!

chaikwa.

 

Put your headlights on relays and your troubles will go away. Been running headlights, running lights, and camper lights all off relays and have not had any problems. I also run my trans cooler fan off an relay.

Using relays is the only way to keep switchs cool.

Jim

 

relays are a good idea most modern vehicles use them, and any headlight switch gets warm, a loose connection will fry them,

 

You have to replace the wire connectors and cut the wire back to the good insulation where it is not burnt. Splice in some wire if needed. An old burnt term will always take out a new switch. Guaranteed.

 

I failed wireing 101 so bear with me.Where are the relays put in the system?Out by the headlights or by the switch???

 

Linked from another site....ignore the site name

Usually helps with the brightness of the headlights


I burnt up a couple headlight switches in my 94 CTD when I had it. I ended up running all running lights off a relay. Only thing that wasn't included was the clearance lights..they weren't on the same circuit I used in the harness. I had so many running lights on the truck and my 48' 3 car hauler, I would just melt the switches. Also the gauge of the wire they used for the running lights was WAY too small to run extra lites on anyways. I always wondered why the wire itself didn't melt. Never had a problem after adding the relay.

Den

 

dido on the relay, still have the second switch and it work real good with all the light from diff trailers. this is a good set up for chevys it will make the head lights brighter