Intermittent Head Light Problem - Dodge Cummins Diesel Forum
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post #1 of 1 (permalink) Old 01-19-2019, 04:24 PM Thread Starter
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Intermittent Head Light Problem

Challenge: Keeping the headlamps on. Safety Issue - Need Help.

1998.5 2500 4X4 Quad Cab SLT; 5.9L (360 C.I.) ISB 24V Cummins; 47RE; Stock (no fog lights). 170K (Use: farming/utility).

Problem: Headlamps (low and/or high beam), and dashboard lights cut-off intermittently.

-- Actuating the headlamp switch (push-pull) restores the lights immediately.

Note: Operate with "headlights on for safety" at all times when on roadways.

Trouble Shooting/Repairs:

(1) Checked multiple grounds (clean and tight);
(2) Checked fuses;
(3) Checked output from generator (steady - approx. 14.5 with "no load"; batteries - new 6/18);
(4) Checked circuits (verified continuity and resistance);
(5) Replaced Column Mounted Multifunction Switch (high beam to low "sticking");
(6) Replaced "Headlamp/Security" Relay;
(7) Replaced Headlamp/Dashboard Combination Switch (Replaced 22 months ago - original failed (partially melted). Note: dashboard above switch - warm to touch.

Note: No DTCs set.

Next Action: considering replacing the Headlamp/Dashboard Combination Switch again. Perhaps the aftermarket replacement switch design is marginal/insufficiently robust to dissipate the heat generated from "continuous on-road use".

Speculation: a "CCD bus communication error" is occurring; pulse from PCM (?) to headlamp circuit may not yield the level of resistance required resulting in the "cut-off". Appreciate any advice to correct this major safety problem. jeepyr

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