Dodge Lost in the Dark...('99 Ram No HEADLIGHTS)

A local farmer dropped off his '99 Ram 2500 Cummins, saying that the Headlights don't work at all...no LOW or HIGH beam action.
He already fired the parts gun with a new aftermarket headlight switch....obviously that didn't fix it.
Let's see if we can restore the Headlights functionality on this old Diesel workhorse the PHAD way...with minimal effort and no extra parts :)
TS100 SOLDERING IRON:
www.amazon.com/dp/B07SQDZ9SV?...
Enjoy!
Ivan

[@crashoverride328]

ACTUAL Factory Service Manual from Chrysler does indeed say ground side switched. There is a known defect in the steering column wiring harness where the wiring is slightly too short and tends to pull wires from the multifunction switch harness which is what we see here. Main suggestion we make for a headlight improvement is to add relays, let the stock wiring activate relays which then use 12 or 14ga wire via fuses from the battery to shorten the power feed and direct feed from the battery rather than via the stock wiring. It stabilizes the power feed and gives full voltage to the bulbs. MUCH brighter and 70% less load on the switch.

[@major__kong]

Essentially what a modern module is doing. Switches and buttons are now just sending signals rather than power directly. If you need to get the current down to nothing or need to use tiny wire, use a mosfet. They basically just need voltage to turn on.

[@crashoverride328]

@@major__kong Relays tend to be easier to come by in most people's parts drawers / junkyard raids. LMC / Aspire Lighting and a few others do HD Relay kits but whichever way, you're improving something which was 'good enough' 20 yrs ago, reducing current load by 4.5A approx per filament and instead driving around 45mA into a relay (Depending on the relay) Parts needed - depends what you have lying around, so could be a Russian Repair if you have them already, either way, as Alex would say 'Better than Factory'

[@senanfoutchedjev2401]

You know, I am ever hardly jealous of other people but for sure I am jealous of your neighbors, to have you around there. Thanks Ivan. Great video.

[@lowbagg]

Work has to wait until I finish watching this.....

[@fredautos]

Haha, it's always a Bit from Ivàn

[@dharley189]

That used to be a common problem on Ford trucks. Wires just barely long enough. Tilt steering wheel would make and break the connection. Great job using smart logical steps despite diagram errors. Del

[@major__kong]

For sharp edges, they make something called grommet edging. It's a flat plastic surface that slips over the metal edge and grips the edge with small spring tabs on either side. A little pricey. So another option is to just take some fuel line, slit it lengthwise, and push it over the edge.

[@randallgoldapp9510]

Finally, one that didn't come from halfway across the country!

[@petepeabody8905]

I can understand the ground wire being compromised by front right turn signal wires, but the wires connecting to the dimmer switch connections was puzzling, Great job Ivan using logic and wiring schematics to easily find and fix the problem

[@russellhltn1396]

Movable steering column? Looks like there's a small lever above the turn signal stalk to allow the steering wheel to tilt.

[@crashoverride328]

In order to switch high / low beam / flash to pass the headlight switch outputs on a single wire to the multifunction switch (Pin 19 - light green) That switch then handles feeding power to the desired headlight level.

[@danamanner9441]

Northridge fix fans are shouting at their screens: "flux is your friend! Excellent diagnosis and NPR fix.

[@scientist100]

What is NPR?

[@milantrcka121]

@@scientist100 In this case, NPR = No Parts Required. Also National Public Radio. And yes, flux is your friend. A slightly bigger flat tip on the soldering iron would help.

[@JoseSilveira-newhandleforYT]

When you can't trust OE diagrams but still hold your north. Only two broken wires and no parts required. Good job, Ivan!

[@crashoverride328]

That OE diagram wasn't very OE - The Chrysler Factory Service Manual for that year IS accurate.

[@JoseSilveira-newhandleforYT]

@@crashoverride328 OK. Bootlegged OE 🙂

[@calholli]

Your OEM diagram shows it with a "central timing module"-- so maybe that was a diagram for "Daytime running lights' included. I noticed your "re-drawn" diagram specifically said it was for non-DRL...... could be the discrepancy, maybe

[@crashoverride328]

Factory Service Manual for the model year still shows ground side switched with DRL or the Sport model's quad bulb lights. My guess is 'OEM' in that case was an aftermarket service manual.

[@robertoconnor3683]

Towed in from Alaska to get a diagnosis. Turn signal doesn't work🤣

[@even7steven]

I feel your pain😂 my 93 dodge showed the symptoms of a bad fuel pump and it was the bulk connector on the column that had a couple loose connections. Must be a dodge thing. Awesome work tracking that down.

[@cstierhoff]

Another great adventure with Ivan. Never a dull moment. Thanks.

[@Sandmansa]

Chrystler products have had issues with wiring in and around the steering collum for quite some time. The wires are usually poorly routed or secured and rub through on something. Thankfully, this was an easy NPR fix. Arguably, the most popular Cummins engines were the old 5.9L 6BT 12 valve with the mechanical fuel injection. But those ended production back in the mid 90's.

[@TheCamperDanFiles]

No parts required repairs are always the sweetest and biggest of wins good job Ivan! Chris.

[@roxanneabbott8424]

Nice work Ivan!!

[@hughjass1274]

Love the short haircut with whitewalls. I bet you could rock an awesome flattop!

[@kylejones1068]

Great video IVAN !

[@dannyhubert9477]

Ivan your parents must be so proud of you and how intelligent you are with any make and models of vehicles you can fix I watch so many of your videos with you Eric I learned alot from both of you guys I want to say thank you and godbless and stay safe and healthy and have great holidays and awesome new year to you and your family

[@carbie5614]

Hello Ivan, I am always amazed how you get to all these wires an fix them. I am working on a 1996 Honda Acord and the wires are under this and behind that, it is crazy my patience goes out the window. good job again

[@shuriKen469]

like a good neighbour, Ivan is there! cheers for sharing this npr repair!!

[@mikechiodetti4482]

Good fix Ivan. Whenever I saw the right t/s indicator on with parking lights or headlights on, it was a bad ground.

[@Garth2011]

Darn diesel engine vibrated the wiring to break ! Actually, bad interior wire loom from the maker and the RF turn signal loom was not fully in the loom. Once I saw the rf turn lamp dimly lit with low beams on I called it a ground problem....finally got one right.

[@GarnConstructionInc]

You had to dig deep for this fix! Just goes to show how much abuse these old trucks have been through.

[@glenharper3136]

Ivan fixed it again. Thanks for the video.

[@MrOverstuffedcow]

Great job Ivan. You make coming home from a hard day's work exciting. I always wondered if one of those beeping wire finders would be helpful for things like this. Sorry, I can't remember the real name of those things.

[@cullenmiller8170]

Nice video and diagnosis. I just ordered an eighty piece kit to unpin connectors since I need to fix a wire that pulled out of the connector on my steering wheel control module to fix my headlight problem.

[@unclemarksdiyauto]

Nice fix! The customer will be so happy to get this truck safetied!

[@phillipmonroy]

Enjoyed the video! Thank you!

[@AP9311]

With funny lights going wonky. Always shoot the ground lol. Nice job Ivan on that trusty 24v Cummins! Love that sounds!!

[@austenj4539]

When a farmer has an issue, you can anticipate having to 'dig deep' before fixing. Turn it into a 'cereal'. 'Wheat' can we expect from a vehicle that 'barley' operates? Nice fix. Not a usual situation to have damaged wires in that location. Bravo!

[@jamesanderson2176]

That is hands down the cleanest "Farm Truck" interior I've ever seen!

[@alanrobison3298]

Those guide posts are a pain! I used to install them on my big truck back in the day and if you didn't wire them right they caused a lot of problems.

[@tacocin]

That 24 valve is a beast!

[@calholli]

yung yung yung yung yung yung yung yung yung yung yung yung yung yung yung yung

[@MTLeopold]

Nice one Ivan. 👍

[@DuaneDonaldson]

When you are in HI, does both HI and LOW turn on? Thanks for checking both OE and Redrawn diagrams. Thanks for another video showing that an understanding of electrical systems is all that is needed.

[@dennisharvey4499]

You could use your croc clip link to hold the wire steady when soldering so you are not pressing against nothing.

[@dustcommander100]

Great job on that weird headlight controls system. I would never have expected the lights to be fed power directly! Reminds me of a funny diag I had one time. My Dad's neighbor call me over and needed help replacing the dimmer switch. I helped him finish, and still no low beams. I checked and both low beams were burned out!

[@PineHollowAutoDiagnostics]

LOL!

[@jimburgess9205]

Nice job, Ivan.

[@danamcintyre3565]

I've run into some grounding problems years back on a Chrysler Pacifica, with fuel pump problems and headlights also and it all came down to a grounding block on the frame on the driver's side under the battery, seems as though Chrysler and I'm sure there are others with the same problem but found the problem being where the wires go into the connector had curoded of the terminals were it bolted for a ground !

[@saint-savageworkshopstpier107]

Hello Ivan, love your channel been watching it for quite a while now. And I have learned a lot from you and Eric O. And I've got to say I own a 2002 C-5 all road and I haven't had one lick of wiring problems like I see on all these American cars that you and Eric O. work on. And from everything I've heard the C-5 allroad's have got nothing but a bad rap on how crappy they were\are Put a period here. And sure they may have some other problems, some mechanical for sure although I haven't experienced any with mine and i've had it for a couple of years now. Just an observation that I've had watching all of these videos' of you guys repairing all these wire problems on mostly american vehicles. Please please keep up the good work that you guys A are doing and of course The honesty that is so important in today's world As has always been, really.

[@sebastiaanfellinga4413]

Thank you so much Greetings from Holland

[@matts3658]

Thanks for the video!

[@johnz8210]

That was nice. Don't forget to get some fall foliage in a video - the colors are awesome.

[@rrmech11]

Nice job Ivan

[@bernardaflores1720]

great job!

[@greghanlon2235]

Good one Ivan.

[@baxrok2.]

Thanks Ivan!

[@elcheapo5302]

The internet: Chrysler is junk! 24 year old Chrysler farm truck with a lot of miles: I have one broken wire.

[@Knight_of_NI]

Morning Ivan, morning, everyone

[@ryandickerson6395]

Ivan, I would love to see a video of you telling the stories of your favorite diagnostic finds/ experiences in the field.

[@PineHollowAutoDiagnostics]

All the fun ones are documented on my channel 😁

[@kevincampbell8298]

Can buy all the parts you want but until the problem is identified its just time and money wasted. The detective hat is so important!

[@jerryking2418]

Absolutely brilliant.

[@robertlacob8831]

I would of gone right to the dimmer switch for the headlamps and checked the ground on the fender area for that turn signal as I always find something wrong with aftermarket installed parts!

[@truracer20]

I have a 2002 F250 Super Duty with a service bed. When I bought it used the turn signals didn't work so I thought Ok, let's check the fuse, it's good so now let's check the flasher, um where is it? Oem wiring diagram said it is in location A (I think location A was the fuse box) nope not there. So I get on the interwebs and find that it is randomly in a harness behind the dash. Some owners have found it behind the radio and others found it down by the HVAC floor vent, others gave up and took their truck to the dealership. Mine was between the two locations... And sure enough whoever previously owned the truck removed aftermarket lights and the turn signal flasher too. I think the oem diagram showed it in the fuse box but it either didn't have a flasher position or it wasn't populated.

[@on-site4094]

Ivan saves another one Them old solid trucks were built to be around for many years. today plastic electronics built to dispose & . Recycle . ♻️

[@anonymuswere]

it's a farm truck and you weren't expecting broken wires? this is actually similar to something that happened to a Mitsubishi I owned. except I had BOTH indicators come in in the car. this was a blessing in the rain, however; in heavy downpours, it would foul out and light all the turn signals steady, serving as substitute DRL. I have yet to have a single vehicle that *HAS* DRL's on it. weird seeing a modern car that doesn't. those auxilliary light wands are actually handy on 94 body Rams because of the big-rig hood design...especially when you're short and trying to drive one of those (even in regular 1500 form)

[@amundsen575]

another good fix. TS100 upgrades, I use a small boost converter 12v to 24V for connecting to car battery, and I use an adapter connected to my dewalt batteries, the largest tip for the TS100 I believe is the TS-C4

[@PineHollowAutoDiagnostics]

The 21V LiPo pack is amazing 😁

[@twl10101]

@@PineHollowAutoDiagnostics Ivan, I also use a 5S lipo for mine. I already had it and use it for power for an old laptop and it has twice the run time of the factory battery(replacements were junk).

[@jdtractorman7445]

Looks like Johnny or Sally bean counter for Chrysler decided to make those wires an inch or two to short. When the tilt column moves, it stretches the wires and they break.

[@robertoruiz7069]

Alex is right ,IVAN it makes a better connection.PERIOD.even if you have core solider with rosin in the middle.I know why you do it your way,it's how you learned,but knowing that flux Floats Impurities AWAY from the joint making it 2x as easy to flow should convince you.We your viewers learn from you ,but here's a chance to learn from US,don't waste this GOLDEN opportunity to learn.May golden showers follow you everywhere!!!haha

[@billziegmond4943]

I worked on a 98 mercury van lights and rear wiper were ground side switched.

[@antonoudenhoven7573]

After you mentioned the rust,I was thinking of 1 thing bad ground

[@blueribb99]

Yes - one drop of liquid flux would have helped. Tarnished metal won't take solder that well.

[@MrJet30]

Amazing!

[@lugnutgmc]

Did this exact same diagnosis on my nephews truck, the ground side switch threw me for a loop!

[@dans_Learning_Curve]

Next parts Canon shot! Complete wiring harness! Would have been the only part that would have fixed this truck!! Great job 👍!

[@DependableAutoTruck]

There was a recall on some of those dealer replaced harness on my 1994 about 5 years ago recall was still active

[@michaelbolt4530]

Fascinating video What make soldering iron is that? And is low temperature solder

[@PineHollowAutoDiagnostics]

See PHAD Amazon Store 👍

[@defendermender4959]

Ivan I find a big tip on the soldering iron is a much better job on automotive, I’m a convert give it a go 👍

[@haroldhawkins9370]

Nice job.

[@brunosperka6933]

Toyota also uses ground side switching. It's cheaper, as the electronics is less complicated. Experienced on a 2008 Hilux in Australia.

[@jamiepatterson1214]

The ground wire for the turn signal being sawed by the sharp edge is understandable. But the wire pulling out of that connector? Not so much. Was someone pulling wires under the dash? Or was it a terrible crimp and truck vibrations caused it work its way out? Whatever the cause, it's fixed and solved the neighbor's truck problem.

[@melvinjones3895]

Oem. just like a JAG look out for fire. But you did another good job.

[@ppeterson9359]

I used AllData’s diagrams for my ‘12 Camry. The OE diagram provided was for a Prius. I contacted AllData and all they could offer was, ‘our diagrams come directly from Toyota.’ I was not impressed :(

[@DaveMathison503]

Ould the steering column aftermarket gauge install hav disturbed that harness ❓

[@ChrisGrazioli]

haha ha. I was just like what the hell why isnt he using flux....

[@fieldsofomagh]

The parts cannon has seized up due to lack of use. May need to be recalibrated. Dem main headlights has me blinded. Need to go down the fields and cut some silage for the moo moos.

[@HotRod-wv4vm]

Awesome

[@riblets1968]

The good news is that you didn't have a Porsche wiring diagram.

[@robpeabo509]

The OEM looked like they were damn near hand drawn! It is somewhat disappointing to see the OEM were incorrect. You would have though5 this would have been picked up prior to release let alone in the last 24 years the vehicle has been out - assuming this model is the first year of that particular wiring diagram.

[@jamespn]

After market, someone’s been here before, I think that the aftermarket modifications seem to cause more issues that age and corrosion.

[@major__kong]

There's nothing wrong with aftermarket per se. A lot of the time it's installation error or poor installation. But it's also sometime related to survivorship bias. Mechanics only see the bad stuff. They never see the good stuff. And what's more likely to fail, OEM or something done in the field? And don't we see enough OEM stuff breaking on this channel?

[@Loglakeliving]

Winning!

[@davidp7163]

Seems like a small wire to be carrying all the current for both high and low bulbs.

[@ehsnils]

At 4:26 both the paths end up at the same grounding point G206.

[@rickchowsr2532]

@NorthridgeFix. Better then factory Ivan. 👊🏼

[@brianw8963]

Oh Chrysler! 👍👍🇺🇸

[@WillKlaver]

.. that green wire powering the headlights needs to be Bigger, i should think..

[@jeffs2809]

Not sure we ever got a full & accurate picture of wiring schematic, with the redrawn being so different from the factory. I do know that headlight switches around that year were high failure point. The aftermarket also sold a kit that added relay(s) so the original switch/wiring becomes relay control rather than direct headlight power.

[@n6dl321]

ah come on Ivan, you used at least an inch of solder

[@dougkubash8673]

Blue, yellow no matter what the color those scotch-locks belong in the trash!!

[@stealthg35infiniti94]

Meanwhile now he has extra parts he doesn't need. 😂

[@sbaker3232]

Cryslur = bad ground

[@jasonmurdoch9936]

Great spelling skills!

[@georgebell3964]

👍

[@johngodley7477]

Good😊 dionogis on the truck😅

[@user-my7hv5ld7b]

rosin core soder has flux in it

[@zx8401ztv]

Well done ivan :-D i would have been walking around cross eyed :-D What a stupid design, im sure the designers are smoking something Dodgy :)

[@axelraver]

15:43 you are not done, you forgot to fix the other almost broken wire next to it friend...

[@htownblue11]

1.5 minutes in and I’m guessing ground fault issue……but I will watch and see how the king would go about it.

[@PineHollowAutoDiagnostics]

That was the easy part 😉

[@gillgetter3004]

NPR YAY👍

[@mattbrown5511]

The parts canon doesn't work without proper diagnostics.

[@catranger01]

Right about now your neighbor's wife is saying " You should have had Ivan fix it instead of firing the parts canon."