1996 Dodge RAM 1500: headlights failing or too dim

Filed Feb 11, 2021 · Body · TX

Headlight switch overheats and the plastic start to melting

Filed Aug 8, 2017 · Lights · 164,000 miles · OH

Takata recall the wiring for headlight switch burnt up and switch melted I saw a lot of the same problems on the internet but no recall on the 1500 just the 3500 for the same problem

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 Apr 13, 2005 · Lights · 93,000 miles · TX

The switch for the headlights must be false since this is already the second time in the two years that I have owned my truck that this has happened. I understand that recalls do occur, but this is very expensive and out of my wallet. Now, I doubt that I will buy a dodge again since dodge does not cover its mistakes.

Filed Dec 2, 2004 · Electrical · 150,000 miles · AL · fire

I have this truck for 2 years and in that 2 years I have many complications with the electrical system. The main problem is the headlight switch melting and burning the wires in the dash. I have had the switch replaced twice and it continues to burn out and melt. I am so scared the truck is going to catch on fire one day that rareley drive the truck. I still have the old parts that were replaced but dont feel it is the switch causing all the problems. I feel it is the whole wiring system. I read the custom reports on mycarstats.com it seems the 1996 dodge dakota had the same problems. There were even reports of the truck catching on fire. If this has already been reported on many differnet occaions; why havent they recalled it??? I would appreciate a response and hopefully dodge taking care of this problem free of charge. Please help!!! [email protected]

Filed Mar 17, 2004 · Lights · 150,000 miles · MO

While driving the consumer noticed smoke coming from the vents. The consumer had taken the vehicle to a mechanic, in which he suggested that the headlight wiring harness switch melted. *ak

Filed Oct 21, 2003 · Lights · 10,000 miles · FL · fire

Consumer called complaining about headlight switch problems. Consumer was aware that there was a recall on the ram 3500 series, but not on the ram 1500, which was the one he had. Dealer was contacted, and sold the consumer a replacement switch. He compared the new switch to the one on the 3500 series, and stated that they were identical.*ak while driving home consumer smelt wires burning and the headlight cut off then came back on. Consumer stated if the switch was the problem on the older model ram's, then they are a problem with his later model. *ph

Filed May 4, 2003 · Lights · AL

I have a 1996 dodge ram 1500 pickup, with 104,000 miles. The head light switch short circuited which caused the wiring connector and the switch connector to over heat and melt. I have purchased a new switch and the auto parts store says this happens often. Also with the switch out of working order I had no lights, this happened at night.

Filed Sep 5, 2002 · Electrical · MD

When headlights are turned on there is a burning smell and smoke coming from dash near windshield. Once headlights are turned off the smoke stops. Vehicle has not been examined by dealer.

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 Oct 13, 2001 · Lights · CA

Headlight switch got hot and melted itself and the electrical connector causing headlights to quit wroking while driving at night. Dash was extremely hot above switch. No other electrical equipment added to headlight circuit. Contacted chrysler but they said it was not their problem. I have the failed components and can provide them or pictures if required. Replacement switch also included a connector and pigtail. Is this because they see this problem a lot? Normally you would have to buy parts separately.

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.