My ignition switch stays at 165 degrees when running. That seems awfully hot! Anyone else had a problem with this?

 

Apparently it's a known issue that involves the A/C blower and headlights.

Do a search for this as well as installing relays to resolve this issue.

 

That's what I found by researching, but it stays that hot whether or not the headlights or blower are on. There's got to be more to it.

 

Yeah, it does sound like it. I do not know why Dodge engineered the wiring to make the ignition switch handle to handle large amp draws like that.

I wonder what else runs through it power wise...

Do you have an amp running along with your radio, or is the sound system completely stock?

 

Try unplugging the circuit barker for the blower motor or unplug the blower motor under the hood. It wont take long to see if this is the problem.

Just my two cents, Mike.

 

I've seen them get warm enough to warp the plastic column cover under the switch, of course that is right before the connector melts and something stops working altogether. I am guessing there is resistance there- either at the connector, or one of the switch's internal contacts- that is causing the heat buildup. The next step may be to disconnect the ignition switch connector while the switch is hot, then feel all the connector's terminals and see if any are really hot. If not, you can assume that either the switch has some unwanted resistance, or there is a component downstream that is drawing too much current.

I think if it was mine, I would replace both the switch AND the connector pigtail and monitor the new one. I hate to throw parts at something but I think the risk vs reward is in your favor.

 

It goes without saying that there is unwanted resistance downstream. It's not the blower motor or the radio and there is no amp. The switch gets just as hot with no load at all other than the fuel solenoid! I've about decided to purchase an RV relay that'll handle 100 amps and trigger it from the ignition switch and feed EVERYTHING downstream off the relay.