headlight switch melted the harness the other week so not wanting to repeat this in the future i removed the switch and the harness, put hi n lo beams on a relay with a toggle switch and the running lights on a 30 amp toggle. i have been smelling a burning plastic smell for a lil bit jus cudnt exactly pin point it until i lost my headlights on a moonless night...that was fun! if you have had you headlight switch burn up with the harness what did you do to fix it? planning on putting lock up on a 3 position toggle soon as well

 

I have seen several headlight switches and connectors burn up over the years, have always replaced the switch and connector with factory stuff, then added a relay to whichever circuit was overloading it. I find the factory stuff will last forever if the load isnt going through it, and it looks like it belongs on the dash. I never really liked the look of a bunch of aftermarket switches on the dash.

 

i like toggles and rockers.......lol

 

What I do on the trucks that aren't eligible for the recall is buy the recall parts kit from the dealer.
Part number CAJM8190
I last paid $62 for one but it's been awhile.
Kit includes everything you need even heat shrink tubing.

 

I did my entire wiring harness for the headlights myself. Bought 2 high power pig tails for the bulbs, $35, 2 40a relays ($15ea) and 2 rolls of 16 gauge wire (for 2 different colors.) and rewired it. Made the lights brighter and less stress on the switch.

 

i have seen those kinds of kits put one in a 05 magnum and it really helped

 

I put SportHeadlights on my truck about 10 years ago, and wired them up to two relays. I've still got the original headlight switch. And the good thing about running the headlights on relays is you can pull back on the Multifunction switch if you want to blast out both hi and lo beams at the same time.

 

you can do that anyway even if you dont have relays.......at least ll of my chryslers (cars and trucks) were able to to that

 

There was a thread many years ago about jumpering the two purple wires in the column to get high-low to work together all the time.