RAM 3500 Truck 4WD V10-8.0L VIN W (1997)
Fig. 7
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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.
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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.
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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.
