Recall - Headlamp Switch: Overview
June 1999Dealer Service Instructions for:
Safety Recall No. 819 - Headlamp Switch
MODELS
1994-1997 (BR) Dodge Ram 3500 Series Trucks
NOTE: This recall applies only to 3500 series trucks built through October 21, 1996 (MDH 1021XX).
IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System.
SUBJECT
Extended operation of the lights on about 79,000 of the above vehicles 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 circuit relay wiring harness must be installed. In addition, the headlamp switch electrical connector must be inspected and any damaged wires must be replaced.
PARTS INFORMATION
Part Number Description
CAJM8190 Headlamp Switch Package
Each package contains the following components:
Quantity Description
1 Headlamp Switch
1 Overlay Relay Harness
1 2-Way Female Connector
1 2-Way Wedge
1 Headlamp Switch Connector
1 Headlamp Switch Connector Wedge
1 Wire Kit (Contains 9 individual wires with terminals at one end)
9 Heat Shrink Tubing
Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Headlamp Switch Packages to service about 25% of those vehicles.
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.
Fig. 1:
2. Open the cup holder and remove the two (2) screws that secure the cup holder assembly to the instrument panel.
3. Remove the cup holder assembly from the instrument panel.
4. Remove the ash receiver from the ash receiver bracket.
Fig. 2:
5. Remove the two (2) screws that secure the ash receiver bracket to the instrument panel.
6. Remove the ash receiver bracket from the instrument panel.
Fig. 3:
7. Carefully pry the cluster bezel away from the instrument panel to disengage the eight (8) snap-clip retainers.
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.
Fig. 4:
11. Remove the three (3) screws that secure the headlamp switch bezel to the instrument panel.
12. Pull the headlamp switch and bezel out from the instrument panel and then unplug the wiring harness connector(s).
13. Pull the headlamp 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.
Fig. 5:
15. Remove the three screws that secure the headlamp switch bezel to the switch mounting bracket and then remove the bezel. Unscrew the plastic mounting bracket (shaft bushing) nut and remove the bezel mounting bracket from the switch assembly. Discard the switch assembly.
B. Install the Parklamp Circuit Overlap Harness:
1. Remove the wedge from the 9-way headlamp switch wiring connector.
Fig. 6:
2. Inspect the 9-way headlamp switch connector and all nine (9) terminals for indications of heat damage.
Fig. 7:
^ Carefully inspect the connector and terminals B1, B2, R and H for signs of damage from overheating (melted connector and/or discolored terminal). If any one of these terminals shows signs of damage, ALL FOUR of these terminals MUST be replaced. Continue with Step 3.
^ Carefully inspect the connector and all other terminals. If any terminals in addition to B1, B2, R and H are damaged, terminals B1, B2, R, H and any other damaged terminals MUST be replaced. Continue with Step 3.
^ If there is no indication of heat damage, continue with Step 6.
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 l 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.
Fig. 8:
5. Insert all of the wire terminals into their proper locations in the supplied connector EXCEPT TERMINALS "B2" and "R". Retape the wiring bundle as necessary.
Fig. 8:
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.
Fig. 9:
7. Insert the wire terminals that were originally in locations "B2" and "R" of the headlamp wiring connector into the supplied 2-way wiring connector. Insert the PINK wired TRACER wire into the (+) cavity. Insert the BLACK w/YELLOW TRACER wire into the (-) cavity. Secure the terminals with the provided 2-way wedge.
Fig. 9:
8. Connect the 2-way wiring connector to the mating connector on the provided overlay relay harness.
Fig. 8:
9. Insert the two wire terminals from the overlay harness into the headlamp switch connector. Insert the PINK wIRED TRACER wire into the "B2" cavity. Insert the BLACK w/YELLOW TRACER wire into the "R" cavity.
10. Secure the wire terminals in the headlamp 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.
Fig. 10:
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.
Fig. 10:
4. Connect the 9-way wiring connector to the headlamp switch.
Fig. 10:
5. Connect the 2-way wiring connector to the headlamp switch (if equipped).
Fig. 10:
6. Connect the single wire connector from the overlay harness to the ground terminal on the headlamp switch assembly.
Fig. 4:
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.
8. Connect the lighter wiring connector.
9. Connect the auxiliary power outlet wiring connector to the power outlet on the cluster bezel.
Fig. 3:
10. Install the cluster bezel and engage the cluster bezel snap-clip retainers to the instrument panel.
Fig. 2:
11. Install the ash receiver bracket. Tighten the bracket screws securely.
12. Install the ash receiver.
Fig. 1:
13. Install the cup holder assembly. Tighten the cup holder screws securely.
14. Connect the negative battery cable(s).
COMPLETION REPORTING AND REIMBURSEMENT
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerClrrysler to record recall service completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace headlamp switch and 08819182 0.5 hours
install overlay harness
Replace headlamp switch, install 08819183 0.9 hours
overlay harness and replace 4 wires
Replace headlamp switch, install 08819184 1.1 hours
overlay harness and replace 5-9 wires
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
PARTS RETURN
Not required.
DEALER NOTIFICATION AND VEHICLE LIST
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL SYSTEM FUNCTIONS 53 AND VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD819".
OWNER NOTIFICATION AND SERVICE SCHEDULING
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is attached.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.
VEHICLE NOT AVAIABLE
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation
CIMS 482-00-85
800 Chrysler Drive East
Auburn Hills, Michigan 48326-2757
ADDITIONAL INFORMATION
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.