Reality: Factory design sucks – well mostlyThe power for your headlights is provided through a long electrical path that includes your headlight switch and headlight dimmer switch. All of this wiring, contacts, corrosion, and connectors compound together to amount to a significant voltage loss.
Headlight output is drastically diminished with the decrease in voltage.Solution: More power to the bulbsbut how?Shorter path to the lights from the battery, also, higher capacity wiring. Usually the wiring in a Jeep is 16 to 18 gauge.
12 – 14 gauge in this application usually is best. Also, a larger gauge short wire can carry more current than a same gauge longer wire. If you are wondering how we can have a shorter path to the lights but still be able to turn them on and off within the cab of the Jeep enter the relay. A relay is a remote switch. A standard relay is turned on by a small amount of current that actuates a magnetic switch and only draws minimal power. The other side of the magnetic switch is another switch that can carry a larger amount of current.
In this case the Jeep’s headlight switch turns on the relay which in turn turns on the headlights.Before I did this on my own Jeep the headlight switch used to get too hot to touch. It eventually failed. This was the point I looked into this upgrade and now the switch does not even get warm due to the small amount of current required by the relay.Parts:. Relays: (2) Use a set of quality relays, remember, these are powering your headlights.
Usually if you are using them you NEED them. Protection: Protect the new circuit with a fuse. These new wires can carry a large amount of current and can cause a lot of bad things to happen quickly if the wrong thing touches a ground source. A useful power tap accessory is an excellent addition to a Jeep.
Painless Wiring makes a nice weather proof fuse block. Wire: Use a minimum 14 gauge for the main power lead and a good ground. Some smaller wire may be used for smaller connections. New headlight plugs. You are going through the troubleno sense in reusing your old corroded light plugs. These are available at most automotive stores.Before you tackle this project make sure you do things neatly and properly. Your vehicle headlights are as important as brakes.
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Know what you are doing! This project involves soldering and vehicle electrical understanding.wiring diagram courtesy ofInstallation:Disconnect the battery before starting.Find the two circuits that go to the headlights. One high beam one low beam, these will become the relay triggers. Select a good location for the two relays. I chose the back side on the drivers of the grill, the factory CJ wires run right through this area and it seemed out of the way.Run a minimum 14 gauge FUSE PROTECTED wire from the battery or positive side of the alternator to the relay.
Run another 14 gauge wire to the relay area to serve as a good ground. Attach a grounding bolt to the grille area near the relays to serve as a good ground distribution point.The relays usually follow the same standard in regard to their pin layout. You can either connect directly to the relays using the slide on connectors or purchase a relay socket to simplify the installation. I prefer the relay sockets (I didn’t use them – but I would if I do it again) and also prefer soldering the connections instead of using crimp-on connectors.Relay pin layouts86 is the relay switching (control) circuit input.85 is the relay switching (control) circuit output (ground)30 is the power circuit input.87 is the power circuit output.
Jeep Wrangler Headlight Upgrade - Here is part 1 of the headlight upgrade. I show how to install a headlight relay kit. This kit will allow the headlights to get power straight from the battery instead of through the factory Jeep harness.Go here to my site for part links:See Hella H4 conversion video here:- You Tube Home PagePower Addicts Playlists- Jeep fix & Repairs- Jeep Sensors- Motorcycle Playlist- Jeep YJ mods- Tools, mods & Creations- Wrangler YJ Maintenance- Jeep Fun- Wrangler YJ Drive shaft repairs- Mustang GT- Automotive Tool Tips-Please watch: 'Jeep Wrangler YJ - How to install Wheel Spacers and why use them.'