I worked at a Dodge dealer for a good while. We had a lot of trouble with those headlight switches. The wiring for the switch, as well as the switch would melt. This was usually caused by towing a trailer with a lot of clearence lights, etc. on it. The circuit just wouldn't handle the load. The fix was to wire in a relay and let it carry the load instead of the light switch. It worked great. The switch is pretty easy to get out. Just remove the cup holder and ashtray. (2 screws each). Then remove the cowling around the instrument cluster. It just pops out. Then undo the headlight switch and pull it out. Look at the wiring/connector at the back of the switch. If any of it's melted or discolored, replace it. The dealer will have the connector as well and it will need to be wired in. Don't worry about the relay I mentioned. That was just my fix. The revised switch will handle the load. If all looks OK, repost and I'll keep trying to help.
Dec 24, 2008 at 9:31 AM
