[Xpress]

Decided that I should upgrade my headlights on the Jeep. As we all know, the stock headlights aren't anything to brag about, and even some of the supposed "performance" sealed beam lights don't put out a lot. The main reason this is so is because of the wiring harness Chrysler decided to use for their lights- the wires are just a bit too small and a lot has to pass through some other components, which lowers the initial output voltage to the headlights, making them dim. You might lose up to 400 lumens (or more if your wiring is at the end of its life), which is a LOT of light (keep in mind our sealed headlights can only put out about 950 lumens at full power).

This is a basic writeup on how to re-wire your headlights so that they can put out the MOST light possible. This can also work for wiring up some auxiliary lights, reverse lights, even sealed beam conversions.

First, we will start off with a basic list of components you will need:

-2x: 85, 86, 87 style 4 pin relays
-2x: 85, 86, 87 style 4 pin relay sockets
-2x: in line fuse holders
-12-14ga wire, about 10 feet of RED and 1-2 ft. of BLACK.
-Soldering iron, good quality rosin core solder, and some basic soldering skills
-Heat shrink tubing
-Heat gun

You can purchase everything from RadioShack if you want or you can get them from Amazon. Amazon is going to have cheaper components, both in price and quality. I bought my relays and inline fuse holders from RadioShack. Cost me almost $20, but they're high quality components.

Nice 12ga wire on them fuse holders.

TO BE CONTINUED

(I still need to pickup some wire and some relay sockets, and other misc. components, hang tight)

 

[WaWheeler]

...............

 

[swells18002]

Hey Xpress,
Did you get the headlight wiring done? If you did, and you remembered to take pictures, it would be great to show post your how to so maybe another member that doesn't know wiring as well can gain some knowledge. It looks like you were headed in exactly the same direction that I went with my previous Ford truck. The headlight wiring in them was substandard also.

 

[Xpress]

Still working on getting around to it, actually. Need to buy some wire still.

 

[Xpress]

I finally decided to attempt to re-wire my headlights today, with the relays.

All began going smoothly, until I actually got to actually using the lights. It took me around 2 hours, but I ultimately decided to de-wire the relays and keep it with the stock setup, considering I have 100W driving lights up front to assist with high beams. The issues I ran into were:

-High beam flash no longer works when lights are off
-Low beams no longer worked
-Lots of cutting and splicing underneath the dash

I was, however, using this diagram:

Looks fantastic, but in reality it is useless unless you have a physical 2 position switch to use. The high beam switch on our YJ's is pretty complicated. I will need to use individual relays, one for high beams, one for low beams, instead of 2 relays tied into each other.

Or basically the following:

One for high, one or low.

 

[swells18002]

When I did my Ford, I tapped into the high and low beam circuit at the headlight. I purchased new plugs for the back of the light. I then used the stock plug for trigger wires for the individual relays. That way I did not have to destroy wiring under the dash and had full function. All the wiring was under the hood. Part of the problem with the Ford was the inferior wiring used for the headlight. It was too small a gauge for the amp draw of the lights.

 

[Xpress]

Tinkered around this morning again. This time I wired the headlights as such:

Don't forget the 20 amp fuse for the RED hot lead.

Will find out just how bright they are tonight...