'04 Dakota blowing brake light fuse daily!

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Ben - 01 Mar 2008 20:13 GMT

HELP!

My 2004 Dakota Quad Cab, 4.7ltr. V8, 5Spd Auto with A/C, Trailer Tow
Group (34K miles) has been popping "stop lamp" or brake light fuses
every day for a few weeks now and I cannot locate the source of the
trouble. Here's what I've done:

1. Trailer Brake System - disconnected and removed, not the source of
the overload or short.
2. The 7-pin connector at the rear bumper, cleaned, additional hitch
light in or out - fuse still pops.
3. Removed, applied elec. connector gel to all brake light bulbs, top
light was loose and burned out, new bulb replaced with gel & some glue
to keep the bulb stable. Fuse still pops.
4. Under dash brake switch inspected, elec. connector gel applied to
slide pin. Fuse still pops.

Could the brake switch be bad, how do I check this??
What else am I missing... other than wiring harness... which I would
rather do anything than trace brake wires for chafing!

Thanks a million to anyone with guidance, direction or assistance!

- Ben (hoping not to get rear-ended in traffic)

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Tom Lawrence - 01 Mar 2008 22:00 GMT

> Could the brake switch be bad, how do I check this??

While I doubt it, the easiest way I can think to check it would be to remove
the connector from the switch, and jumper the +12V feed to the brake lamp
output (simulating what the switch would do). My guess is that's still
going to pop the fuse.

> What else am I missing... other than wiring harness... which I would
> rather do anything than trace brake wires for chafing!

Unfortunately, I think that's your most likely fault... somewhere in the
wiring harness something has gotten chafed, pinched, or whatnot, and is
shorting out. Pull all the bulbs, and check for continuity between the
brake +12V feed and ground (pull the fuse, and measure from the unpowered
leg of the fuse socket). Have someone watch the meter, while you jiggle the
wiring underneath the truck.

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Ben - 23 Mar 2008 19:59 GMT

FOUND IT!
The wiring bundle under the dash, drivers side was resting on the top
of the parking brake assembly. Each time I pushed the parking brake,
the top of the pedal rubbed, chafed and wore 5 wires in the harness. I
have separated them, taped, sealed and spliced the damaged wires.

Let this be a cautionary notice to all other Dakota owners to check
the placement of their wires under the dash.

Thanks for your help!- Ben

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Bob M - 24 Mar 2008 18:42 GMT

> FOUND IT!
> The wiring bundle under the dash, drivers side was resting on the top
[quoted text clipped - 6 lines]
>
> Thanks for your help!- Ben

Good job! Thanks for reporting back with the results.

Bob

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