1994 DODGE RAM 2500 Electrical System Problems

I WAS DRIVING HOME AT NIGHT WITH $105 WORTH OF GROCERIES AND ALL OF A SUDDEN MY HEADLIGHTS JUST QUIT WORKING AND IT WAS PRETTY DARK COULDN'T SEE ANYTHING SO I HAD TO PULL OVER AND STOP AND WAIT FOR SOMEONE TO COME PICK ME AND ALL MY GROCERIES UP BECAUSE I COULDN'T DRIVE HOME WITHOUT HEADLIGHTS

Mileage: 88,956

AFTER DRIVING APPROXIMATELY 30 MIN, THE HEADLAMPS INTERMITTENTLY LOSE POWER, SOMETIMES STAYING OFF UNTIL THE SWITCH IS MANIPULATED TO RE-ESTABLISH THE ELECTRICAL CONNECTION. SLIGHT BURNING ODOR ACCOMPANIES INCIDENT. *TR

Mileage: 344,000

DRIVING DURING THE DAY WITH LIGHTS ON (LOW BEAM) AND SMOKE AND THE SMELL OF BURNING PLASTIC BEGAN POURING OUT OF THE UPPER LEFT PORTION OF THE DASH. THE FAILURE WAS THE LIGHT SWITCH WHICH WAS BURNT AND SO WAS THE PLASTIC CONNECTOR. THE DODGE DEALER WAS AWARE OF THE PROBLEM AND I WAS TOLD BY THE PARTS PERSON THAT IF I JUST REPLACED THE SWITCH WITH OUT PUTTING IN AN UPDATED WIRING HARNESS THAT THERE WAS A 100 % PROBABILITY THAT THIS INCIDENT WOULD OCCUR AGAIN. WAS TOLD THAT THERE WAS A REPLACEMENT PART (SWITCH AND WIRING HARNESS) FOR $88 WHICH WOULD ALSO TAKE TWO HOURS OF SHOP TIME TO INSTALL AND THAT, ALTHOUGH THEY WERE AWARE OF THE PROBLEM, THERE WAS NO RECALL. I DID KEEP THE ORIGINAL SWITCH. *NM

Mileage: 248,400

ON TWO OCCASIONS IGNITION SWITCH WIRES CAUGHT ON FIRE. THIS CAUSED THE PLASTIC AROUND THE IGNITION TO MELT. DEALER INFORMED THE CONSUMER THAT THERE WAS A RECALL, BUT THIS VEHICLE WAS NOT COVERED UNDER THE RECALL DUE TO VIN. *AK

Mileage: 114,000

CLOCK SPRING HAD TO BE REPLACED DUE TO AIR BAG SENSOR LIGHT STAYING ON WHILE TRAVELING , AND INOPERATIVE HORN AND CRUISE CONTROL. DEALER WAS NOTIFIED, AND MADE REPAIRS. *AK THE MANUFACTURER DECLINED REIMBURSEMENT, CONSUMER REQUESTED REIMBURSEMENT BECAUSE RECALL CONDITIONS WERE NOT MET. *YH

FRONT END OF VEHICLE HAD TO BE REBUILT FOUR TIMES, REPLACING VARIOUS COMPONENTS INCLUDING TIE RODS/ STABALIZER BARS, ETC. SUSPENSION PROBLEMS LEAD TO POOR HANDLING CONTROL,AND IS UNSAFE FOR OPERATION ON THE ROAD. ALSO, IN MAY OF 2001 AFTER STARTING ENGINE, IGNITION WOULD NOT STOP TURNING WHICH CAUSED SMOKE TO COME FROM THE ENGINE COMPARTMENT. PLEASE PROVIDE ANY ADDITIONAL INFORMATION/ATTACHMENTS.*AK

THE TRUCK COULD NOT BE TURNED OF, THE IGNITON SWITCH WAS LOCKED OUT BECAUSE THE CONTACTS IN THE STARTER SOLENOID RELAY HAD WELDED SHUT. THIS PREVENTED THE STARTED BENDIX GEAR FROM DISENGAGING AFTER THE VEHICLE STARTED. ON THE DIESEL TRUCK, THIS ALSO CONTROLS THE FUEL SHUTOFF RELAY. WITH THE SLOENOID CONTACTS WLEDED SHUT, THE CIRCUIT COULD NOT BE DE-ENERGIZED, SO THAT THE IGNITION SWITCH WOULD WORK PROPERLY AND ALLOW THE TRUCK TO SHUT OFF. AS A RESULT, THE STARTER SOLENOID DRASTICALLY OVERHEATED, CAUSING A DIRECT SHORT WHICH CAUSED A FIRE IN THE WIRING HARNESS.IT ALSO CAUSED THE FUEL SHUTOFF SOLENOID TO OVERLOAD, BURNIG IT AND ITS WIRING HARNESS.THE ONLY WAY TO SHUT DOWN THE VEHICLE WAS TO DISCONNECT BOTH NEGATIVE BATTERY TERMINAL CABLES FROM EACH OF THE BATTERIES.THE STARTER SOLENOID THAT OVER HEATED AND SHORTED OUT IS DIRECTLY BELOW AND SLIGHTLY OF TO THE SIDE OF THE DIESEL FUEL DRAIN.HAD I NOT HAD IN MY POSSESSION A SMALL ADJUSTABLE WRENCH TO REMOVE THE BATTERY CABLES, THE TRUCKS ELECTRICAL SYSTEM WOULD HAVE ENTIRELY SHORTED OUT AND MOST LIKELY CAUSED A SERIOUS ENGINE COMPARTMENT FIRE.THE MANUFACTURER HAS KNOWN OF TIS DEFECT FOR MANY YEARS, AT LEAT AS FAR BACK AS 1995.IT COULD HAVE BEEN AVOIDED HAD THE MANUFACTURER USED A BETTER QUALITY CONTACT SET ($30.00). THE FACTORY INSTALLED CONTACT SET IN THE SOLENOID IS GROSS DESIGN FLAW.MY WIFE AND I WERE VERY LUCKY THIS TIME.*AK

THE TRUCK COULD NOT BE TURNED OF, THE IGNITON SWITCH WAS LOCKED OUT BECAUSE THE CONTACTS IN THE STARTER SOLENOID RELAY HAD WELDED SHUT. THIS PREVENTED THE STARTED BENDIX GEAR FROM DISENGAGING AFTER THE VEHICLE STARTED. ON THE DIESEL TRUCK, THIS ALSO CONTROLS THE FUEL SHUTOFF RELAY. WITH THE SLOENOID CONTACTS WLEDED SHUT, THE CIRCUIT COULD NOT BE DE-ENERGIZED, SO THAT THE IGNITION SWITCH WOULD WORK PROPERLY AND ALLOW THE TRUCK TO SHUT OFF. AS A RESULT, THE STARTER SOLENOID DRASTICALLY OVERHEATED, CAUSING A DIRECT SHORT WHICH CAUSED A FIRE IN THE WIRING HARNESS.IT ALSO CAUSED THE FUEL SHUTOFF SOLENOID TO OVERLOAD, BURNIG IT AND ITS WIRING HARNESS.THE ONLY WAY TO SHUT DOWN THE VEHICLE WAS TO DISCONNECT BOTH NEGATIVE BATTERY TERMINAL CABLES FROM EACH OF THE BATTERIES.THE STARTER SOLENOID THAT OVER HEATED AND SHORTED OUT IS DIRECTLY BELOW AND SLIGHTLY OF TO THE SIDE OF THE DIESEL FUEL DRAIN.HAD I NOT HAD IN MY POSSESSION A SMALL ADJUSTABLE WRENCH TO REMOVE THE BATTERY CABLES, THE TRUCKS ELECTRICAL SYSTEM WOULD HAVE ENTIRELY SHORTED OUT AND MOST LIKELY CAUSED A SERIOUS ENGINE COMPARTMENT FIRE.THE MANUFACTURER HAS KNOWN OF TIS DEFECT FOR MANY YEARS, AT LEAT AS FAR BACK AS 1995.IT COULD HAVE BEEN AVOIDED HAD THE MANUFACTURER USED A BETTER QUALITY CONTACT SET ($30.00). THE FACTORY INSTALLED CONTACT SET IN THE SOLENOID IS GROSS DESIGN FLAW.MY WIFE AND I WERE VERY LUCKY THIS TIME.*AK

BRAKING SYSTEM WORKED INTERMITTENTLY. HAD BRAKE MASTER CYLINDER REPLACED 3 TIMES. ALSO, ELECTRICAL PROBLEMS/HEADLIGHTS GOING OFF AND ON/POWER WINDOWS GOING UP AND DOWN, AND DOOR LOCKS LOCKING AND UNLOCKING WHILE DRIVING. DODGE REPLACED ENTIRE ELECTRICAL SYSTEM UNDER WARRANTY. VEHICLE HAS BEEN TO DEALER 74 TIMES UNDER WARRANTY, DEALER CAN'T FIND CAUSE OF PROBLEM ON BRAKES.*AK

BRAKING SYSTEM WORKED INTERMITTENTLY. HAD BRAKE MASTER CYLINDER REPLACED 3 TIMES. ALSO, ELECTRICAL PROBLEMS/HEADLIGHTS GOING OFF AND ON/POWER WINDOWS GOING UP AND DOWN, AND DOOR LOCKS LOCKING AND UNLOCKING WHILE DRIVING. DODGE REPLACED ENTIRE ELECTRICAL SYSTEM UNDER WARRANTY. VEHICLE HAS BEEN TO DEALER 74 TIMES UNDER WARRANTY, DEALER CAN'T FIND CAUSE OF PROBLEM ON BRAKES.*AK

VEHICLE EXPERIENCED FAILURE OF THE RECALL COMPONENT (00V-135) ON SEVERAL OCCASIONS PRIOR TO RECALL NOTIFICATION CAUSING SEVERAL COMPONENT FAILURES, OWNER REQUESTING REIMBURSEMENT. *MJS

HEADLIGHTS STOPPED WORKING ONE NIGHT AND WOULD NOT COME BACK ON. TOOK VEHICLE TO DEALER FOR A RECALL. WHEN THEY TOOK OFF THE DASHBOARD THEY NOTICED WIRES TO THE HEADLIGHT SWITCH WERE MELTED.*AK

HEADLIGHTS GO ON & OFF WITH TILT WHEEL (DEALER FIXED BY REPLACING SWITCH AND TAPING BURNED WIRES :( ). FAN AND POWER WINDOWS FUNCTION WITH KEY REMOVED FROM VEHICLE WITHTILT WHEEL IN UP POSTION REMOVAL OF COLUMN COVER SHOWS BURNED RUBBER EXPOSED WIRES. PROBLEM HAS RENDERED THE UPPER FUSE BOX WITH NO POWER AND NO HEATER OR POWER WINDOWS. ALL THESE PROBLEMS OCCURR FROM THE WHEEL PINCHING THE WIRES INSIDE. AT TIME S A BURNING ODOR CAN BE SMELLED.

TRANSMISSION SLIPS AT 50MPH. TRANSMISSION ALSO DISENGAGES FROM OVERDRIVE AT 65- 70 MPH. THIS HAS HAPPENED MANY TIMES. DEALER HAS NOT FIXED IT YET. PCM HAD BEEN REPLACED IN 1995.PCM REPROGRAM IN 1997. TRANSMISSION HAS HAD BANDS ADJUSTED IN 1997 . TO DATE OVER DRIVE UNIT HAS NOT BEEN CHECKED OUT. THIS PROBLEMS ONLY HAPPENS WHEN IN OVERDRIVE .WHICH MAKES ME THINK OVERDRIVE UNIT NEEDS TO BE REBUILT. HAVE HAD THREE MISS REAR ENDS IN JUNE 17,1999 BECAUSE OVERDRIVE WOULD DISENGAGE,AND TRANSMISSION SLIPPING AT 30 MPH,50 MPH ON JUNE 17,1999 DEALER IS ORDERING OVERDRIVE SWITCH , THINKS THIS IS THE CAUSE .HAVE A CHRYSLER FILE #5902303. *AK

CABLE TO RIGHT POSITIVE BATTERY TERMINAL HAS TO BE CLEANED AND TIGHTENED REGULARLY, OR EVENTUALLY WILL NOT START.

AUTO-TRANSMISSION; SYSTEM UP SHIFTS TOO QUICKLY @ TOO LOW A SPEED CAUSING ENGINE TO HESITATE AND VIBRATE. PLEASE DESCRIBE DETAILS. TT