Headlight Switch Malfunction on 2003 Dodge RAM 1500 4x4
05 January 2004
05 January 2004Search Words: Head light won't turn off stays on Symptoms: Headlights started to not turn off. The lights would usually turn off with repeated turning on and off of the switch. Sometimes the lights would just come on "by themselves" after I had walked away from the truck. Later the lights would not go out at all. Leaving the light switch in "parking lights" mode would turn off all lights when the ignition was off, but the battery would go dead. (I suspect the computer was kept on by the light switch in the "parking lights" position.)
The Problem: The problem turned out to be that the gold plating on the "switch" circuit board had flaked off and was bridging the circuit board traces. I suspect that the gold plating was too thick.
The Fix:Remove the light "switch" module by pulling off the lower dash panels below and near the head light switch, including the panel that is above the drivers knees and shins. I don't remember the specifics, but I was impressed on how well it was put together with many re-snapable clips (not like older vehicles in which the snaps always broke when trying to undo them) and a few screws. Remove the "switch" module. I quote the switch as it is not a switch of old. The light switch and dash dimmer are more like digital encoders. Both controls move sliders that have about 8 fingers that slide over a circuit board, each with 4 intermittent parallel traces. Once the module is removed, remove the 3 or 4 screws on the back of the module. The module more or less comes apart into 2 pieces, the controls with the slider fingers on one side, and the back with the control circuit board on the other. I think there was one thing that fell out. My impression that it was made well in that it was hard to put it back together wrong. Gently remove all grease and gold flakes from the circuit board and switch fingers. I used tissue and Q-tips. Make sure to get them all and that there are no flakes bridging the circuit board traces. Re-grease. Silicon grease is probably best, but I only had standard automotive grease. Seems to have worked okay, but it will probably dry out in a few years. Re-install the switch module.
Remove the light "switch" module by pulling off the lower dash panels below and near the head light switch, including the panel that is above the drivers knees and shins. I don't remember the specifics, but I was impressed on how well it was put together with many re-snapable clips (not like older vehicles in which the snaps always broke when trying to undo them) and a few screws. Remove the "switch" module. I quote the switch as it is not a switch of old. The light switch and dash dimmer are more like digital encoders. Both controls move sliders that have about 8 fingers that slide over a circuit board, each with 4 intermittent parallel traces. Once the module is removed, remove the 3 or 4 screws on the back of the module. The module more or less comes apart into 2 pieces, the controls with the slider fingers on one side, and the back with the control circuit board on the other. I think there was one thing that fell out. My impression that it was made well in that it was hard to put it back together wrong. Gently remove all grease and gold flakes from the circuit board and switch fingers. I used tissue and Q-tips. Make sure to get them all and that there are no flakes bridging the circuit board traces. Re-grease. Silicon grease is probably best, but I only had standard automotive grease. Seems to have worked okay, but it will probably dry out in a few years. Re-install the switch module.Other notes: I have not see a service bulletin on this, nor heard anyone else having problems with this. This would probably be covered under warranty, but I'm 5 hours from the Dodge dealer.
