Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Dodge Ram 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
Dodge 1996 2500 cummins diesel - VIN - [redacted]. Started truck, starter remained engaged, turned key off, starter remained on and engine running, smoke rose from the engine compartment, only way engine could be stopped was to disconnect the batteries. By the time batteries were disconnected, the starter, fuel shutdown solenoid, some wiring were burnt up, had to be replaced. Luckily electrical fire went out before igniting diesel fuel.
The steering column on this truck has gotten very hot under the ignition switch area. So hot in fact that the wires and plastic column cover have smoked and melted through. I feel there May be a fire soon. The dealership says nothing is wrong with my model year but the melted hole in my steering column says otherwise I've read there was a recall of this nature but was told in no uncertain terms that they would not be helping me. Help...
On the morning of 12/7/09 I started my truck to warm it up with the heating fan on high when at some point, somewhere in the wiring harness under the dash overheated and started the interior on fire. Destroying my vehicle. The windshield and driver door windows were broken from the heat but luckily remained intact and not letting air inside to fuel the fire and it eventually extinguished itself.
While driving at 65 MPH and with the air conditioner running smoke drifted out of the vents. Consumer took the vehicle to a mechanic, who determined that wires were burnt in the steering column.
I drive quite a bit during the night time with my vehicle. There seems to be a very serious issuse with the wiring over heating at the headlight switch. I have replaced 5 ... Going to be 6 headlight switches. There is a dangerous amount of head being put out at the switch itself. So much that it actually melts the pigtail at the light switch connection. The light switch itself is destroyed. Its bad especcially when driving down the road and your headlamps, marker lights and dash light all go out. If I do not have a replacment part in my truck at the time, I have to find a spot in between switch position just to get my lights operational to "limp" my truck home. My choice of positions when the switch fails is headlamps with out markers and no dash lights or fog lamps markers and dash lights. Being Dodge has such terrible headlamps I use fog lights to drive when this happenes. …
Several years back ignition switch was recalled for burning up. At that time had replaced ignition switch twice previously. Dodge paid for the switches and labor and replaced ignition switch with new and improved ignition switch. Now approx. 5 to 7 years later ignition switch burning up again taking out door lock, windows, air bag, and abb lights are all on and you cannot operate either window or door lock. Took into shop in spring, texas called rileys of rayford road in spring, texas where they informed me that the ignition switch causing all of these problems and needs replaced again! Called demontron Dodge in conroe, texas to see about switch replacement. Nothing yet!
Numerous headlight switches replaced due to them burning up to include several inches of the existing wiring harness to switch. I cannot believe that this type of safety issue is not being addressed. You dam sure have knowledge of the problem since the aftermarket auto parts o reilys etc. Carry the switch or switch with wiring harness as an option. After reading here all switches go out about the same... The headlights start going on and off then look for smoke coming from around dash where switch mounted. You can feel the heat from under when switch is burning up. Need a simple relay to stop this show how much Dodge loves its customers!
Dt: consumer stated he filed a complaint on 7-16-05 odi # 10129534. He has not heard anything from this yet. He wanted to file another complaint because he says there is a recall on the following component: electrical system: ignition: switch . Recall #00V135000. He said someone from Chrysler came out on 7-22-05 and took some pictures and asked him a lot of questions. He has been calling the manufacturer all day and he can not reach anyone his truck is located at national Dodge in jacksonville, nc .he wants to get his vehicle fixed and returned to him.
Starter came on while driving vehicle at 40 MPH. I parked vehicle and turned off the ignition switch and removed the key, and starter kept running. Smoke was coming from under the hood from the battery cables. I disconnected the batteries and the starter stopped. The dealer said the recall for the ignition switch wiring had nothing to do with the starter. I believe there was a short in the ignition wiring that caused the starter to come on. I can not imagine how a starter solenoid could get powered without turning the ignition switch or a short.
Normal driving. Truck has 138K miles. Headlights fail. Initially they go off, come on, then go off permanently. Can smell smoke from dash wiring harness. Manufacturer has a recall #819 that covers the 3500 series trucks with identical wiring and headlight switch part numbers, but will not cover the 2500 series trucks. This is a safety hazard and I have found multiple instances on the internet of other people having the same exact problem. Left unchecked, I'm certain this will result in a dash fire, property damage, and possibly death.
Electrical complaints in other Ram 2500 years
Frequently asked questions
How common are electrical problems on the 1996 Dodge Ram 2500?
NHTSA has 26 complaints about the electrical system of the 1996 Dodge Ram 2500, 9% of the model year's 291 complaints. The component named most often is wiring › front underhood (3 mentions).
Is there a recall for 1996 Dodge Ram 2500 electrical problems?
No. NHTSA lists no electrical system recall for the 1996 Dodge Ram 2500. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 1996 Dodge Ram 2500 electrical problems start?
Half of the complaints with a recorded mileage happened before about 145,000 miles.
Is it dangerous?
Owners linked 0 crashes, 8 fires and 0 injuries to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.