dash harness

[Rockyrocco]

I took apart my instrument cluster and found that the harness plug to the headlight switch was damaged [looks slightly melted] I was wondering if the plastic plug could be replaced or do I need a new harness .

[myk]

Couldn't you just pull the wires out of the plug and plug each wire onto the corresponding terminal on the switch?  As long as the end of the wires are insulated properly and don't make contact with anything else other than their proper terminal you should be fine...

[Ghoste]

I would want to find out why it was melted first.

[cowboy4x4n]

Mine had been melted as well.  I noticed my headlight switch got hot as hell.  Burn if u touched it after its been on a while.  I just bought a new switch to see if that was the problem

[myk]

I would want to find out why it was melted first.

It's a common problem on these cars, which is why some of the members here including myself have done the headlight relay/upgrade modification.  With the relays installed you only need a fraction of the alternator output to fully power the headlights, as opposed to stock where you have that much more current flowing through the wires and the headlight switch itself, which is why they tend to get hot and melt.  Mine was ok but I did the relay install regardless; headlights are stronger, brighter, with less dimming at idle in gear and now my tired headlight switch doesn't have to host all of that energy anymore...

[cowboy4x4n]

not to hijack the thread, but what is the relay upgrade if you dont mind.

[myk]

not to hijack the thread, but what is the relay upgrade if you dont mind.

http://www.dodgecharger.com/forum/index.php/topic,168.0.html

It's a good read, I recommend it to everyone.  You can actually see in the dark after doing this 'mod, even with the brake lights, heater, radio and with the car stopped and idling all at once...

[AirborneSilva]

Thanks for posting the link myk 

[cowboy4x4n]

update for anyone interested in this thread.  I purchasd a new headlight switch from year one.  only 35 bucks thank god.  replaced the melted headlight switch connector and did the relay upgrade Myk suggested.  Thanks Myk.  The headlight switch no longer gets hot, the headlights are super bright and I am one happy guy.