NHTSA Complaint #740433 — 1994 DODGE RAM 2500

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