Wiring problems of the 1997 Dodge Ram 2500

Consumer noticed there was smoke coming from the dashboard above the headlight switch while driving. Immediately consumer turned the engine and the headlights off. After a couple of minutes it stopped smoking. After waiting several minutes, the engine started, but the headlights would not come on. Consumer called dealership, and was informed that there was no recall for make and model. Dealership has not checked this vehicle. Consumer checked the NHTSA website and found a recall for the 3500 series but not the 2500 series. Discovered this is not an isolated incident. Vehicle has not been repaired yet due to expense.

When the consumer pulled out of a gas station, there was a smell of plastic burning. Suddenly flames appeared under the hood. The mechanic stated the main bolt for the 120 amp vibrated off, which caused the wiring to heat up and catch fire.

The engine would not stop running. Wiring to fuel solenoid started burning. Engine started to shutdown and the starter engaged. This appears to be common because a cummins dealership mentioned that it happens often on Dodge trucks and so did another Dodge dealership once the vehicle gets around or above 75,000 miles. The new solenoid is different from the original. How ever Dodge says that the vehicle is out of std warranty and will not assist. If reserached you will find that in other applications this engine does not appear to have a problem with the solenoid.

Around 6 months ago a plume of thick black smoke exited the engine compartment. I inspected the engine but could not locate the source and figured it might have been something falling on the exhaust system. Recently I discovered melted and corroded wires leading to the fuel preheater. No fuse was blown. I have not taken this vehicle in for repair yet, so the cost estimate is simply a guess. If a short existed in the preheater, then the fuse should have blown. Either the fuse is to large, or the wire size is too small for the application.