Lights flicker, and check engine light comes on. Recently done a DIY service.

super_saffer · Oct 27, 2020

Did a big (for me) service on my 04 Durango 5.7 LTD 4x4 over the last few weeks, as part of regular maintenance and chasing a stalling issue. I've had some issues resurface with the headlights flickering, not coming on (but flashing brights work), or then not going off. Check engine light has also come on for the first time, when turning the lights on yesterday.

I've already got a replacement steering column Multi Function Switch (which I haven't installed), but if I mess with the dash headlight switch the lights will sometimes work properly...so I just ordered a replacement for that too.

Doesn't seem to stall anymore though, which is fantastic, but in focusing on that I forgot about the lighting issues which were popping up before it started stalling.

I'm at 108k miles for the vehicle. What I recently did:

Oil Change (Valvoline full synthetic);
Oil Filter Change;
Spark-plug change (champion coppers);
Spark plug boot change;
Spark plug wiring change;
PCV Valve change;
Throttle body clean & repair of chafed power wiring;
Clean electrical switches:
Oil Pressure Switch change;
Crankshaft Position Sensor change;
Camshaft Position Sensor change;
Gas cap change;
Replace passenger side headlight bulb housing which was melted/burnt;
Replace headlights with standard Sylvania replacement;
Replace all other lights (interior & exterior) with LED;
Replace brittle or missing black plastic wiring protection;
Replace fog light housing (F - you Dodge engineer who thought that needing to take the freaking bumper cover off to access the fog light housing was a good idea. It was honestly the hardest part of all this!)

This is a heck of a lot more than I've ever done on a vehicle before so I'm quite chuffed with myself for not making any issues worse 🤣

If only I could fix the lights now....

super_saffer · Oct 27, 2020

Oh, and if I disconnect the battery for a minute then the check engine light does not come on again until I mess with the dash light knob.

DuRonbo · Oct 27, 2020

Wow....lots of work there! Good job!

Need the codes(s) for the CEL to really be able to help for that.

Flickering headlights sounds like either bad connections at the battery or going to the alternator. How old is your battery? How do the battery post clamps look?

super_saffer · Oct 27, 2020

DuRonbo said:
Wow....lots of work there! Good job!

Need the codes(s) for the CEL to really be able to help for that.

Flickering headlights sounds like either bad connections at the battery or going to the alternator. How old is your battery? How do the battery post clamps look?

Thanks! I managed to find the MOPAR service manual online, which helped a ton.

Battery 'looks' new but I've only had the vehicle a few months so I don't know. I cleaned the terminals that connect to the battery when I did the service, but I didn't clean the other ends. Would it still be a battery/alternator issue if the headlights won't turn off? That made me think for sure it would be a switch, but I did have issues on my Mustang with corroded battery cables. Can I check anything myself with a multimeter?

I'm waiting for a scan to arrive, so I can check codes. It'll be here in a few days, and I don't need to drive the 'Rango.

DuRonbo · Oct 28, 2020

Nothing I can add until you get the code(s). Maybe the new headlight switch will help?

I'm guessing there are two separate issues? Flickering usually is a charging/voltage stability issue hence the alternator and connections I mentioned. The headlights not turning off could be the switch or something worse such as the FCM or some connection/corrosion issues at the IPM, etc.

super_saffer · Oct 28, 2020

DuRonbo said:
Nothing I can add until you get the code(s). Maybe the new headlight switch will help?

I'm guessing there are two separate issues? Flickering usually is a charging/voltage stability issue hence the alternator and connections I mentioned. The headlights not turning off could be the switch or something worse such as the FCM or some connection/corrosion issues at the IPM, etc.

Fingers crossed it's not a FCM then! Scan tool arrives this weekend (maybe the switch too, but next week for sure) so I'll follow up then.

Thanks!

DuRonbo · Oct 28, 2020

I think you can use the key trick to check for basic codes with a 2004.

Ignition off-on-off-on-off-on. Engine off. Cycle ignition key without starting vehicle quickly within a few seconds. End up with ignition in the ON position. Codes will show in the odometer display. If more than one code they will cycle through display and when done display will show done.

Try that.

AJWaller · Oct 28, 2020

My 07 started flickering when its cold on the the passenger light... BUT ONLY after I switched the stock headlights to LEDs did it start. I even bought the anti flicker module for it. As I only drive 7 miles each way I just grin and bare it myself. Have thought about switching lamp with driver and seeing what it does and then switching module from one side to the other to see if maybe bad mod. But thats to much work.. JK JK

super_saffer · Oct 28, 2020

DuRonbo said:
I think you can use the key trick to check for basic codes with a 2004.

Ignition off-on-off-on-off-on. Engine off. Cycle ignition key without starting vehicle quickly within a few seconds. End up with ignition in the ON position. Codes will show in the odometer display. If more than one code they will cycle through display and when done display will show done.

Try that.

Thanks I tried that a couple times just now but no dice. I have not turned the lights on again though, after disconnecting the battery so the check engine light isn't showing. I guess I'm nervous to mess with it too much as I know the electronics are old and probably are sensitive to whatever is messing with it. I will swap out the switch when it arrives, then try the lights again with the real time monitoring tool that should arrive soon.

AJWaller said:
My 07 started flickering when its cold on the the passenger light... BUT ONLY after I switched the stock headlights to LEDs did it start. I even bought the anti flicker module for it. As I only drive 7 miles each way I just grin and bare it myself. Have thought about switching lamp with driver and seeing what it does and then switching module from one side to the other to see if maybe bad mod. But thats to much work.. JK JK

Only the headlights and foglights are still standard, and not LED. Mainly because 1 headlight when out a couple weeks ago on a trip and I bought brand new bulbs from an auto parts store in some town. Bulb and wiring were faulty in the end, so it didn't matter. Flickered just the same before I swapped out any bulbs with LED's.

cerd · Oct 29, 2020

Bring it to an Advance Auto Parts store and have them check the alternator and battery. Their tool will give you a print out of how much it is putting out, voltages, etc as well as condition of battery. The test is free. You can also have them read for codes while you are there. Also free.

Regarding the lights, I had an issue where my low beams were not coming on unless I pushed the dial. It turns out my switch assy was bad. I replaced it since with an aftermarket for $30 from Amazon with the fog light control on the dial instead of the tiny button that I had to feel around for. I haven't had a headlight issue since.

super_saffer · Oct 29, 2020

cerd said:
Bring it to an Advance Auto Parts store and have them check the alternator and battery. Their tool will give you a print out of how much it is putting out, voltages, etc as well as condition of battery. The test is free. You can also have them read for codes while you are there. Also free.

Regarding the lights, I had an issue where my low beams were not coming on unless I pushed the dial. It turns out my switch assy was bad. I replaced it since with an aftermarket for $30 from Amazon with the fog light control on the dial instead of the tiny button that I had to feel around for. I haven't had a headlight issue since.

Thanks for the tip! Unfortunately I just moved from the US to small town Canada, and so my options are quite limited for parts stores and assistance there. I could take it straight to a mechanic, but I just really want to figure this out on my own and learn what I can.

I've ordered a new headlight switch and a scan tool, both of which should be here in a few days, and will report back then. I'm going to straight up replace the switch first (because I've had the ship it from the US anyway), and then try the lights again with the real time scan tool plugged in. I

super_saffer · Nov 2, 2020

DuRonbo said:
I think you can use the key trick to check for basic codes with a 2004.

Ignition off-on-off-on-off-on. Engine off. Cycle ignition key without starting vehicle quickly within a few seconds. End up with ignition in the ON position. Codes will show in the odometer display. If more than one code they will cycle through display and when done display will show done.

Try that.

Well, the vehicle started stalling again. Still no check engine light and no code except P1684. An internet search says it a code saying the battery has been disconnected recently. Still having issues with the lights flickering, and with them not turning off. New light switch has yet to arrive.

What's next to check? Alternator?

super_saffer · Nov 2, 2020

super_saffer said:
Well, the vehicle started stalling again. Still no check engine light and no code except P1684. An internet search says it a code saying the battery has been disconnected recently. Still having issues with the lights flickering, and with them not turning off. New light switch has yet to arrive.

What's next to check? Alternator?

I can faintly hear what sounds like metal on metal (bearing?) if I listen to the alternator. Not loud though.

cerd · Nov 2, 2020

You could have an auto parts store bench test the alternator...Before taking that route, I would check for corrosion and a firm grip from the terminals on the battery.

super_saffer · Nov 4, 2020

Going to start a new thread as this has wandered away from the original title. Battery and alternator have been tested, and both are fine. It's the switch that needs replacing. Stalling issue is something else...

Lights flicker, and check engine light comes on. Recently done a DIY service.

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DuRonbo

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DuRonbo

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DuRonbo

AJWaller

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cerd

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cerd

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