1996 Dodge RAM 1500: engine overheating

Filed Feb 11, 2021 · Body · TX

Headlight switch overheats and the plastic start to melting

Filed Jul 17, 2012 · Electrical, Lights · 141,000 miles · NC

In the 1994-2001 model year dodge ram 1500, 2500 and 3500 trucks there is no relay in the wiring circuitry use for the headlights. When the ram was redesigned in 1994, the engineers did not find it necessary to change the 40-year old design for the headlight system; feeling only the need to use a larger gauge wire to handle the excessive heat of the halogen bulbs. Unfortunately, neither the wires nor the switch or internal rheostat (for the instrument panel lighting) could handle this load and the following near tragic even has been an all too common occurrence. A recall (or at the very least a tsb has been issued for the 3500 model dodge rams, which are comprised of the exact same switch and wiring, but nothing has been noted about the 1500 or 2500 models. I cannot understand this, and this is the very reason I feel compelled to be writing this complaint in the first place. One night I was driving along the freeway at about 55-MPH when the headlight switch, relay and connected wiring all became overheated, causing them to melt. Becoming frantic, I was able to quickly wiggle the dimmer switch (combination/turn signal switch), then the headlight switch until I got them to come back on. During that episode I had them go out on me about 4 times that I recall. Currently the vehicle remains unfixed and is not drivable at night. Being a mechanic, my first thought was to check the relays and fuses to see if they were blown or bad. To my dismay, I could not find any relays! This was how I discovered, through some online research, about the recurring problem with the headlight switch- how I was not alone in this situation and the rest of the aforementioned paragraph. I will gladly be available for phone calls, questions, and to take pictures of the parts in question.

Filed Aug 31, 2003 · Electrical · 159,000 miles · OK

I took my 1996 dodge ram to the dealer for an ignition switch wiring recall. After the recall parts were replaced, my truck was not fixed. The wiring harness had overheated and damaged my ignition switch. This cost more money. There was also a special tool that my husband had to purchase to change the ignition switch. The plastic cover on my steering column had aslo melted. I would say my truck was very close to going up in flames. This is very upsetting to me because I feel this part should have been replaced along with the harness since the defective wiring caused this part to be damaged. I think dodge should add this part to the list of parts changed when they service vehicles from this recall. I also believe they should reimburse me and anyone else who has had this problem. There was almost a fire, I know this because I have the old ignition switch and the plastic part on my steering column has a hole where it was hot, since I did not see a fire (my husband did smell something burning), I cannot answer yes to the question below that asked "was there a fire?". Any help would be greatly appreciated. I think something should be done before someone is seriously injured or killed. Something similar happened to a friend of mine who had a different make car, her son burned to death in a car. I shiver to think what might have happened if I had not found out about the recall on this vehicle.

Filed Jun 27, 2002 · Lights · SC

Headlight switch would overheat when headlights are turned on. Dealer contacted. Feel free to provide any further information.

Filed May 30, 2001 · Engine, Steering · MA

On april 19, 2001 while traveling on rt 495 in wareham ma the fan on my l996 dodge 1500 2 wheel drive sport pickup truck suddenly became unattached from the water pump shaft causing the fan to fly into the radiator and puncturing same.at the same time due to the loss of the belt that drives the power steering pump,and water pump causing difficult steering and engine overheating I immediately stopped in the breakdown lane. When this occurred the vehicle had 57159 miles.

Filed Dec 10, 2000 · Transmission · OK

Dealer replaced transmission quick cooler connect per notification. Dealer left fitting loose, resulting in fluid leak at 15720 miles. I complained to chrysler headquarters. Chrysler said they would consider goodwill assistance if problem develops after warranty. In june 2000, at 49898 miles, trans failed. I paid $100 deductible on trans overhaul per goodwill assistance file 7360750. A few days later, seal failed and pumped out trans fluid. Dealer replaced seal. In sept 2000, dealer couldn't find reason for trans overheating at 54480 miles. In nov 2000, trans failed at 57426 miles. Dealer finally agreed to replace with remanufactured trans. In dec 2000, trans failed again, at 57492. I have been out tow bills and not lender vehicle.

Filed Nov 15, 1999 · Lights · VT

Headlight switch failed due to overheating which caused headlights to go out while vehicle was traveling on interstate at 65mph. Dealer sold me a new switch/kit and provided installlation information for their safety recall 819 (which they said did not apply to this vehicle). Instructions talk about looking for a melted connector which indeed my switch does have. New wiring harness provides a resistor or something which my mechanic tells me is to dissipate heat! Dealer and chrysler can not explain why this happened and offer no relief but I still feel if they know they have a problem and are making modifications to some of the vehicles why they are not required to make them on all of them, especially when the failure occurs without warning and you are left without lights! Fortuantely I had fog lights and the presence of mind to turn them on! Thank you.

Filed Sep 14, 1999 · Lights · KS · fire

Headlight switch overheats and catches on fire. All the lights in the dash will go out. Also. Dealer has sent an updated owners manuel.

Filed Jun 17, 1998 · Transmission · KY · fire

While driving the transmission overheated, causing transmission fluid to leak onto the manifold, resulting in a vehicle fire. Please provide any details.