Headlight Switch problems of the 1996 Dodge Ram 2500

The contact owns a 1996 Dodge Ram 2500. While driving approximately 70 mph, a burning odor and smoke emitted inside the cabin. The headlight switch ignited into small flames. The vehicle was maneuvered to the side of the road where the contact extinguished the flames. A fire and police report were not filed. There were no injuries. The contact was able to drive the vehicle. The vehicle was taken to the dealer, who stated that the fire was contributed to a faulty headlight switch. The vehicle was not repaired. The manufacturer was notified of the issue. The approximate failure mileage was 200,000. The VIN was unvailalbe.

When towing a trailer the headlights shut off for a few min. Then come back on. With the brights on the shut offs happen earlier in the drive and more frequently. Dodge did a recall on the 3500 trucks with the same headlight system, but they did not recall the 2500 trucks. All the electrical power for the headlights is routed threw the headlight switch. The switch heats up and the headlights are shut off or the headlight switch melts from the heat and they never come back on. Dodge even sells a fix for the problem which uses relays, which they should have used when they built the truck.

Attempted to turn on headlights. Headlight switch pulled out from dis-integrated instrument panel plastic. Had to release steering wheel and hold body of headlight switch with one hand while operating switch control with other hand. This Dodge ram's dash cover has completely cracked away several years ago. Now, the actual instrument panel is dis-integrating. Currently the headlight switch, the overdrive switch and auxillary power outlet are hanging by wires. The drink holder and radio are removed as their mounting support is gone.

Early morning, dark, some fog, mountain roads, 45 to 55 speed limits. Using high beams as needed but not constantly due to fog and some oncoming traffic. Headlights went out,flashed back on and off,seemed to happen a couple of times as I was breaking and trying not to hit something or go into a ditch. Hit dimmer switch and low beam lights came on. Stopped at next available safe pullout. Checked truck over,found nothing. Resumed trip. Lights went out again,using high beams,finished trip with only low beams and had no other problem. Checked out headlight switch,and found overheated wiring that could result in fire.

After using headlights on high beam for approximately 15 minutes, went to switch to low beam and lost all lighting. Upon examination, headlight switch was melted. This is the second switch that has done this.

Numerous headlight switches replaced due to them burning up to include several inches of the existing wiring harness to switch. I cannot believe that this type of safety issue is not being addressed. You dam sure have knowledge of the problem since the aftermarket auto parts o reilys etc. Carry the switch or switch with wiring harness as an option. After reading here all switches go out about the same. . . The headlights start going on and off then look for smoke coming from around dash where switch mounted. You can feel the heat from under when switch is burning up. Need a simple relay to stop this show how much Dodge loves its customers!.

: the contacted stated when stopped on the side of the road, a burning odor was noticed and the parking/running lights had failed to illuminate. The fuses were checked and found to be good. The vehicle was taken to an independent service mechanic. On inspection, the problem was identified as a failure to the headlight switch, due to melted wiring. The service dealer and manufacturer were contacted. Updated 12/05/06.

Subject:recall on Dodge Ram 2500 comments: in 1999 you had a recall on all Dodge ram 3500 pickups, 1994-1997 for the headlight switch, lights may go out, recall # 819. My 1996 Dodge Ram 2500 has the exact same switch and my headlights did go out and I almost had an accident. Why was this pickup by-passed on this recall. It is very dangerous for the lights to go out at 65 mph on a dark night. From NHTSA web site.

Headlight switch keeps overheating due to faulty wiring. Consumer replaced switch 4 times. Dodge is aware of defect, and has designed new part which includes an extra relay.