DodgeRam.info > TSB's > Recalls > Recall 819

Recall # 819

Headlamp switch

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Date:  June 1999

models:   1994-1997 (BR) Dodge Ram 3500 Series

NOTE: This recall applies only to 3500 series trucks built through October 21, 1996 (MDH 1021XX).

subject:
Extended operation of the lights on about 79,000 of the above can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning.

repair:
The headlamp switch must be replaced and a parklamp relay wiring harness must be installed. In addition, the headlamp switch electrical connector must be inspected and any damaged wires must be replaced.

Parts:

CAJM8190    Headlamp Switch package

Service Procedure:

A. Remove the Headlamp Switch Assembly:

1.    Disconnect the negative battery cable(s)

Note: To enhance customer satisfaction, remember-to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, -. etc.) when you have completed the service procedure.

2.    Open the cup holder and remove the two (2) screws that secure the cup holder assembly to the instrument panel (Figure 1).

3.    Remove the cupholder assembly from the instrument panel.

4.    Remove the ash receiver from the ash receiver bracket.

5.    Remove the two (2) screws that secure the ash receiver bracket to the instrument panel (Figure 2).

6.    Remove the ash receiver bracket from the instrument panel.

7.    Carefully pry the cluster bezel away from the instrument panel to disengage the eight (8) snap-clip retainers (Figure 3).

Figure 3

 

8.    Unplug the wiring harness connector from the lighter.

9.    Unplug the wiring harness connector from the auxiliary power outlet.

10.   Set the cluster bezel aside.

11.   Remove the three (3) screws that secure the headlamp switch bezel to the instrument panel (Figure 4).

Figure 4

12.   Pull the headlamp switch and bezel out from the instrument panel and then unplug the wiring harness connector(s).

13.   Pull the headiamp switch control knob out to the ON position stop.

14.   Depress the switch knob and shaft release button on the bottom of the switch assembly and then pull the switch knob and shaft out of the switch (Figure 5).

15.   Remove the three (3) screws that secure the headiamp switch bezel to the switch mounting bracket and - then remove the bezel (Figure 5).

Figure 5

16.   Unscrew the plastic mounting bracket (shaft bushing) nut and remove the bezel mounting bracket ftom the switch assembly. Discard, the switch assembly.

B. Install the Parklamp Circuit Overlay Harness:

1.    Remove the wedge from the 9-way headlamp switch wiring connector.

2.    Inspect the 9-way headlamp switch connector and all nine (9) terminals for indications of heat damage (Figure 6).

 
Figure 6
Figure 7

3.    For vehicles with headlamp switch wire terminal and connector heat damage: Remove any damaged wire terminals from the headlamp switch connector using a small screwdriver, Miller Special Tool #8197 or equivalent. If the connector is also damaged and cannot be reused, remove all wires and discard the connector.

4.    Replace any damaged wires as determined in Step 2 as follows:

a. Cut the electrical tape and remove the affected wire(s) from the bundle.

b. Cut off the damaged wire approximately 10 inches from the terminal.

    NOTE: Stagger the wire splice locations by about 1/2 inch.

c. Remove about 1 inch of insulation from the end of the wire.

d. Remove about 1 inch of insulation from the end of the matching color and gauge wire and terminal provided in the parts package.

e. Slip one piece of the provided heat shrink tubing over the new wire end.

f. Twist the exposed wire ends of the harness wire and the replacement wire end together.

g. Solder the twisted wire ends together using rosin core solder.

   CAUTION: All wiring splices must be soldered or future circuit failure may occur.

h. Slide the heat shrink tubing over the wire splice and heat the tubing until the tubing shrinks tightly around the wire and sealant comes out both ends of the tubing.

i. Repeat Steps A-H for all other damaged wires as necessary.

5.    Insert all of the wire terminals into their proper locations in the supplied connector EXCEPT TERMINALS "B2" and "R" (Figure 8). Retape the wiring bundle as necessary.

 Cavity 
Wire Identification
B1
Red w/Light Green Tracer
B2
Pink w/Red Tracer
B3
Light Blue
D
Pink w/Dark Blue Tracer
H
Light Green
I
Tan w/Orange Tracer
P
Light Green w/White Tracer
R
Black w/Yellow Tracer
U
Black w/Light Blue Tracer

6.    For vehicles WITHOUT headlamp switch connector or terminal heat damage: Remove the PINK w/RED TRACER wire from location "B2" and the BLACK w/YELLOW TRACER wire from location "R" of the headlamp switch connector using a small screwdriver, Miller Special Tool #8197 or equivalent (Figure 8).

7.    Insert the wire terminals that were originally in locations "B2" and "W' of the headiamp wiring connector into the supplied 2-way wiring connector. Insert the PINK w/RED TRACER wire into the (+) cavity. Insert the BLACK w/ YELLOW TRACER wire into the (-) cavity (Figure 9). Secure the terminals with the provided 2-way wedge.

8.    Connect the 2-way wiring connector to the mating connector on the provided overlay relay harness (Figure 9).

Figure 9

9.    Insert the two wire terminals from the overlay harness into the headlamp switch connector (Figure 8). Insert the PINK w/RED TRACER wire into the "B2" cavity. Insert the BLACK w/YELLOW TRACER wire into the "R" cavity.

10.   Secure the wire terminals in the headiamp switch connector with the provided 9-way wedge.

C. Install the Headlamp Switch Assembly

1.    Install the headlamp switch bezel bracket on the new switch assembly.

2.    Install the headlamp switch bezel on the mounting bracket. Tighten the three (3) mounting screws securely.

3.    Install the switch knob and shaft on the new switch assembly by depressing the release button on the bottom of the switch assembly and then inserting the shaft into the switch assembly (Figure 10).

4.    Connect the 9-way wiring connector to the headlamp switch (Figure 10).

5.    Connect the 2-way wiring connector to the headlamp switch (if equipped) (Figure 10).

6.    Connect the single wire connector from the overlay harness to the ground terminal on the headiamp switch assembly (Figure 10).

7.    Tuck the relay pack into the instrument panel pocket on the left side between the demister duct and the HVAC duct and then install the headlamp switch into the instrument panel. Tighten the three attaching screws securely (Figure 4).

8.    Connect the lighter wiring connector.

9.    Connect the auxiliary power outlet wiring connector to the power outlet on the cluster bezel.

10.   Install the cluster bezel and engage the cluster bezel snap-clip retainers to the instrument panel (Figure 3).

11.   Install the ash receiver bracket (Figure 2). Tighten the bracket screws securely.

12.   Install the ash receiver.

13.   Install the cup holder assembly (Figure 1) Tighten the cup holder screws securely.

14.   14. Connect the negative battery cable(s).

Additional notes:

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances:

 
Labor Operation Number
  Time Allowance  
Replace headlamp switch and install overlay harness
08819182
0.5 hours
Replace headlamp switch, install overlay harness and replace 4 wires
08819183
0.9 hours
Replace headlamp switch, install overlay harness and replace 5-9 wires
08819184
1.1 hours

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions


Thanks to Bob Bergevin for supplying this Recall information.

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This page was edited on: May 3, 2004