Automotive headlight systems are a bit more complicated, because you need a smaller "switch" to flip the larger one. Attach the new high power feed wire to the 30 terminal on both relays. Big thanks to BrianM over at FEP for helping me out. Installing a relay kit is super easy. The two headlamps are connected together, as normal, and taken to Pin 87 of the relay. 4) Slide the 1Ú2" heat shrink onto the 1Ú4" stripped side of the wire then crimp the ring terminal on, slide the heat shrink over the crimp to cover the exposed wire, then shrink it with a heat gun or torch (be careful!) the relay ground wire got disconnected when other work was done on their car. Vanagon – headlight relay upgrade. Fully understand it before starting. Joined: Apr 2, 2017 Location: Louisville, Kentucky. Attach the 56b wires to the low beam relay. Now, as far as I know, the wiring is the same for at least 86+ 5.0 and SVO cars and I’d imagine it’s the same for all 79+ fox chassis cars but don’t quote me on that. New headlight plugs. However, I wanted to make sure this wouldn’t happen again so I decided to add the relays now rather than later. Well, bit the bullet and plunked down a chunk of change to have a " custom made"relay … This is the entire assembly mocked-up in location. 87 is the power circuit output. Headlight Relay Harness Kit made by Speedway Motors, for as low as $39.99. Verify that it is the same style of relay as the replacement relay. With no known headlight relay upgrade to be seen. 4.6 out of 5 stars 51. The 4 Headlight cars don't use the 6024 headlight, that's the 2 headlight cars. Ripping Gears – Scaring Dad! Why and How to Upgrade Your Headlamp Circuit. Your email address will not be published. Once they are connected, soldered and protected with heat shrink it’s time to start buttoning everything up. 's relay kit to the headlight circuit. Attach the low beam circuit feed from the headlight switch to the 86 terminal on the low beam relay. Everyone has seemed to hear of this but it continues to mystify many. Run a minimum 14 gauge FUSE PROTECTED wire from the battery or positive side of the alternator to the relay. You are going through the trouble…no sense in reusing your old corroded light plugs. This project can be completed in an hour or two by someone experienced in Jeep wiring. They are plug-and-play. That’s why I’m putting this together. Once all my soldering is complete and I’m 100% happy with everything I will tighten permanently. I tossed around building one from some wire terminals, relay sockets and such. The difference will be Night and Day! This is a rather simple conversion with drastic results. They are NOT up to the job. Fox chassis cars are known for having headlight issues…everything from flashing lights when the fogs are on, to blown headlight and multi-function (turn signal) switches. If you still have the factory headlight setup on your T25 you will no doubt be well aware that light output is scarily small at best. Now, connect the blue wire (or pole 86) from relay 1 to the side of the Red/Black wire that is coming from the back of the car (this actually goes to the headlight switch)…then connect the yellow wire (or pole 87) from the same relay (relay 1) to the end of the Red/Black wire going to the front of the car (actually going to the headlights). A lot of guys buy factory style headlight connectors to make a 100% plug-n-play harness – and as much as I like plug-n-play I didn’t want to go that way. You can barely see the blue and yellow wires to the right…these will be hidden once the coil cover is re-installed. Protection: Protect the new circuit with a fuse. Attach the new high power feed wire to the 30 terminal on both relays. Step 3: Remove the old relay. Reassemble the headlights and clean up all the wires using wire ties and/or flexible wire molding. This upgrade would also allow for the use of modern halogen bulbs—which produce significantly more viewable light than incandescent. I need something simpler! Cut the Red/Black wire. 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. Don't want any confusion with 4 headlight guys ordering those as they are WAY too big for the 5.25 headlight bucket. Just a simple stud insulated around a plastic mounting base. I tucked the wires I soldered back into the harness bundle and re-taped…looks factory! They're generally pretty … Now, connect the blue wire (or pole 86) from relay 2 to side of the Green/Black wire that is coming from the back of the car (this actually goes to the headlight switch)…then connect the yellow wire (or pole 87) from the same relay (relay 2) to the end of the Green/Black wire going to the front of the car (actually going to the headlights). to Pin 86 of a standard ISO automobile relay. Do what you like. Burnout cam! One high beam one low beam, these will become the relay triggers. By Daniel Stern. 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. As mentioned above my starter solenoid was full so I needed another option. I had my dad drive in front me of during the day just to make sure everything was ok and that my lights stayed on! I cut everything to size based on where/how I wanted to mount it. A few weeks ago I was on the way home from a show in the Capri and I realized I didn’t have any headlights. 1966-1967 Dodge Charger Forum. Headlight socket pin layout The system can be further improved by adding M.A.D. However, with as many threads that there were over there (and elsewhere), there wasn’t anything that was super simple and stupid proof. Even with good bulbs, and good connections- we all still have old light units. Basically because all the power goes directly through those 2 switches and they can’t handle the load. I would like to put relays in to just use the switch as a trigger and feed them Headlight relay upgrade - 332-428 Ford FE Engine Forum Easy 10 minute installation. I first had to move my 3g alternator wire from the starter solenoid to the new distribution stud so the new jumper wire I had made would fit. Our Headlight Relay Kits are designed to allow your stock headlights to perform to their fullest. WAY better! A relay is a remote switch. SHC VW Mk 2 Golf Headlight Relay, Wiring Loom, Upgrade. When I did my original tear down and rebuild, I ordered new Hella H4 headlights as an upgrade to the old CJ sealed beam enclosures. Who offers the headlight relay kits (for a 67 Chevelle) that runs full voltage to the headlights? The overall goal other than safer headlights was for this to be simple and easy to do and maintain if needed. I’ve joined the 2 black ground wires (or pole 85 of the relay) together with a lug connector and heat shrink. H4 9003 Headlight Relay Wiring Harness Kit, H6054 H4 Socket Plugs H4 Headlamp Light Bulb Ceramic Socket Plugs Relay Harness for Ground Triggered H6054 H5054 H6054LL 6014 6052 6053 Headlights. Attach the low beam circuit feed from the headlight switch to the 86 terminal on the low beam relay. In this case the Jeep’s headlight switch turns on the relay which in turn turns on the headlights. Products to Compare (max of 3) X. You can either connect directly to the relays using the slide on connectors or purchase a relay socket to simplify the installation. At this point it was time to mount my distribution stud. 30 is the power circuit input. Here is a shot after everything was complete. Verify all connections are correct and connect the battery. I’ve also joined the 2 red power wires (or pole 30 of the relay) together and then to the 10awg fuse holder. Simple fix, but, lots of sellers won't, wouldn't or can't do that. ALL of the power load goes through the switches, connectors, etc. I thought this was the perfect spot. PARTS/TOOLS list (based on exactly how I did it): First thing I did was to remove the battery and tray from the car. ... a no-name or off-brand relay could easily kill you when it fails on a dark road somewhere, ... the headlight switch. The harness then drives two big relays, one for each headlight. 3) Cut 4 pieces of 1/8" heat shrink. This project involves soldering and vehicle electrical understanding. It eventually failed. Compare These Parts Talk to the Experts. Also, the standard relay pigtail is plenty long enough to reach the headlight wires so I don’t have to lengthen anything! lol. 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. Jeep Headlight upgrade - Install relay kit. The relays usually follow the same standard in regard to their pin layout. Just a quick question: how many here have done the relayed headlight wiring upgrade? See below for pics/details. As mentioned above we’ll be using the Red/Black wire (low beams), and the Green/Black wire (high beams). Page 1 of 3 1 2 3 Next > Aug 3, 2017 #1. Adding relays to the mix takes the load off the switches along with providing brighter lights since power is coming directly from the battery! Select a good location for the two relays. YES is the answer of course!...this kit is the perfect cost effective solution for you! Light up the way! Home > Headlight relay upgrade. Attach the 85 terminals to the new ground source. Once I got all the soldering out of the way I double checked everything and buttoned it all up. Call 800.979.0122, 7am-10pm, everyday. I found a headlight relay harness on Amazon that was very reasonably priced and had the ceramic ends installed. Rotating Headlight relay modification. The only upgraded headlight relay I've seen works only on the 240 with the square plugs. American Autowire headlight enhancement relay kits supply 12 V directly to the headlights, while existing wiring controls the relays. Do a bit of research to find out which wires and where you’ll need to tap into before getting started. Test the headlight operation. I know you can piece everything together DIY style, but I'd rather just pick up a kit and be done with it. Attach the high beam circuit feed from the headlight switch to the 86 terminal on the high beam relay. No wiring needed Turn up the volume! A useful power tap accessory is an excellent addition to a Jeep. The fuse holder will tuck in nicely just above the relays. 85 is the relay switching (control) circuit output (ground) The control relay is N/C. I’m addicted …, Out for a cruise with Dad. Misc self-tapping screws for mounting the relays, Soldering iron (you can use butt connectors and heat shrink but I always prefer to solder wires), 2 lug connectors (1 for ground to chassis and 1 for power from starter solenoid. ... That's a good,easy upgrade … Take the load off the system and wire your lights directly to the battery! VW T25 T3 Vanagon Headlight Relay / Wiring Loom Upgrade. The power for your headlights is provided through a long electrical path that includes your headlight switch and headlight dimmer switch. Just a quick clip …, When doing a gear swap – ALWAYS change the bearing …, VIDEO UPDATE – 10-23-2012 – Another 10sec ET for Dad. Cut the Green/Black wire. Hidden by the coil cover, dry and easily accessible if need be. Once I was happy with how the assembly was going to mount it was time to start wiring the actual lights. I decided to tap into the stock headlight wiring that is in a harness bundle under the battery tray (NOTE – This is in my 86 Capri so the battery is on the driver’s side). A couple close ups of the stud with everything mounted to it. VIDEO Update, VIDEO UPDATE – Exhaust Cam V2 – Way better this time, https://www.youtube.com/watch?time_continue=1&v=-XpT4G14Kmw. I searched eBay, Summit & Jegs and came up dry. 2 relay sockets with pigtails and diodes – you can also make your own pigtail with push on connectors but the pre-built pigtails are SO much easier and nicer looking! Get it as soon as Thu, Feb 4. Once they are connected, soldered and protected with heat shrink move on to the other wire…. Wire: Use a minimum 14 gauge for the main power lead and a good ground. Leave a reply. Fox chassis cars are known for having headlight issues…everything from flashing lights when the fogs are on, to blown headlight and multi-function (turn signal) switches. Find the two circuits that go to the headlights. Order ships free when this item is included and exceeds $99. These are available at most automotive stores. What? Our 18 piece kits are plug-and-play and include everything you need to install them. Solution: More power to the bulbs…but how? Messages: 252 Likes Received: 50. By n20capri September 19, 2012 Tech. Attach a grounding bolt to the grille area near the relays to serve as a good ground distribution point. Usually the wiring in a Jeep is 16 to 18 gauge. 31 is ground. 56a is the high beam feed. FREE Shipping on orders over $25 shipped by Amazon. I had a spare headlight switch but that didn’t do anything – It ended up being the multi-function switch…the more expensive of the 2 but an easy fix none-the-less. All of this wiring, contacts, corrosion, and connectors compound together to amount to a significant voltage loss. I didn’t like the idea of having to build a huge harness going from one side of the car to the other. No good reason we can think of. Thanks again for sorting the group buy out You can purchase pre-made harnesses but they are expensive – the parts for the entire job are cheap, even with adding in a little bit of time it was a no-brainer for me – I love DIY projects anyway so this was a perfect project! Everything at this point is still loosely mounted. H4 Wiring Harness Upgrade for any vehicle with the H4 light plug Increase your OEM lighting output by a minimum of 50% (usually more) Save your light switch from burning up like they always do. 2007 Wrangler Unlimited JK 4 Door Hits Dealer, Dana 30 and Dana 44 Front Axle Castor/Camber Adjustment with Correctors, New book about building and modifying your 1997-2006 Jeep Wrangler TJ, Copyright © 2021 Sevenslot Media | MH Magazine WordPress Theme by MH Themes, 4 Door Wrangler JK Freedom Top Hanger DIY, 2012 Wrangler Model Changes and Compatibility, Old Man Emu YJ Springs in a CJ Rear Install, President Bill CB with Firestik Antenna Installation, Rugged Ridge Montana Replacement TJ Soft Top, jeepfan.com 2018 JL Wrangler Unlimited Rubicon Project. Totally hidden. Lights – NOTE: It may be easier to remove the headlights and their bezels to work on the inside grille wires. As mentioned this is optional and there are a bunch of other ways to accomplish the same task. Perfect for what I need. wiring diagram courtesy of Daniel Stern Lighting. Below is the relay setup after I prepped it once I knew exactly how I wanted to mount it. Improving the performance of your vehicle’s headlights is one of the most … Usually if you are using them you NEED them. Upgrading your Jeep’s headlight circuit is a rather straight forward process and can provide that much needed nighttime light without the addition of expensive driving lights or replacement headlights. For those that dont know, the factory wiring for Chrysler back in the day did not use relays to turn the headlights on. I was just surprised at the high voltage I had before !!! I located the bundle underneath and started peeling away the factory wrapping to reveal the wiring underneath. Know what you are doing! I created this to be bare bones easy to read and follow. Run another 14 gauge wire to the relay area to serve as a good ground. Sometimes they even melt and have been known to cause fires! 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. This is the distribution stud. Track Order. Results in brighter headlights with no dimming when other accessories are turned on. The existing lo/hi beam wires from the dimmer switch will activate the relays. Lights – NOTE: It may be easier to remove the headlights and their bezels to work on the inside grille wires. This is a close up of the wire bundle – Here you’ll notice a Red/Black wire and a Green/Black wire – these are the 2 we need. As these looms look the business 👍 I will leave it in anyway. This should help make sense of everything. Since the 4-headlight system was introduced in 1988-up GM Fullsize pickups and Suburbans, owners of these vehicles have wondered why their low beams go off when the high beams are turned on? If it is hard to grasp, you can use a pair of pliers, needle nose or otherwise. Most put a relay in when they update to halogen (more draw) or just to bypass the resistance in the old worn headlight switch/wiring connections anyway. 1 distribution stud with jumper cable (optional) – my starter solenoid was full so I needed an alternate power source. Some smaller wire may be used for smaller connections. A relay uses a tiny bit of power from the headlight switch on your dashboard to "flip" another, bigger switch, which turns the headlights on. Of course you’ll want to mock everything up on your car to figure out exactly where you will be mounting everything. If you wish to, a separate wire from the fuse can be used for each relay and can be colour-coded the same as the corresponding headlamp wire. Each wire will be associated with a different relay. The blue and yellow wires will be going to the bundle above to wire the actual lights…more on that later. To access the headlight closure relay, you will need to remove the cover or lid from the fuse box. After some research on FEP and help from other friends I figured it was either of those 2 switches. Simply plugs into the 240 Plus everything would have been “under” the car requiring me to jack it up and crawl around – that’s like work! Aug 6, 2017 #1. The headlight closure relay will pull directly out from its terminal. Relay pin layouts Headlight output is drastically diminished with the decrease in voltage. You remove the existing connectors to the headlights, and connect one of them to the new harness (which has the correct connector to plug right in). At the time I ordered I had the best intentions, and even had the Painless wiring relay kit in the Cart; before the total came $$$ and the headlight … New headlight relay harness upgrade for Datsun 240Z, 1970-73. I got a distribution stud and a jumper cable made up. Painless Wiring makes a nice weather proof fuse block. 95. Here you can see the jumper wire from the solenoid to the dist stud and how I have everything routed to the new stud. Plug 'n Play design. Attach the 56a wires to the high beam relay. I could have simply gone directly to the battery but I wanted a cleaner look. I love wiring and am good at it but I hate dealing with wiring that I didn’t do – even if it’s factory wiring! Does your Mk2 Golf suffer with poor visibility while driving at night? Attach the 31 wires to the new ground source. There are a million headlight relay upgrade wiring diagrams out there…even for different make/model cars but they are all very confusing IMO. The other end of the jumper wire will go on the new dist stud along with the 3g alternator and the power wire from the relays! Can’t hurt to be safe. I will be mounting them side-by-side just like this. An easy way to tell if your stock headlights are not performing optimally is if they appear to have a yellow hue to them when the vehicle is running. I have the ground wire coming up between the relays. Required fields are marked *, I recently got into making 3D printed parts. Still have some room on there for a couple more things! Luckily, I could hold the turn signal stalk so my bright lights worked and I was able to get home but I certainly had to fix the issue. In this video I show you how to install a High Beam Headlight Relay upgrade kit, to make your GM truck give off more light. We make the very best Headlight Relay Kits that money can buy! Why not? Relays: (2) Use a set of quality relays, remember, these are powering your headlights. In almost all vehicles built through the late '90s, and quite a few built after that timeframe, all … This wiring upgrade will allow a full 12 volts off of the battery to reach your headlights while still maintianing all of your factory switches. Enter headlight relay harnesses. Enjoy! So either the headlights flash or go off all together so the switch can cool down or the switch just blows. VIDEO UPDATE – Exhaust cam teaser. It’s super simple and easy to follow. Again, more research on FEP pointed me in the right direction. Attach the 85 terminals to the new ground source. 2 @ 1Ú2" for the ring side and 2 @ 5/8" for the male terminal. Also, a larger gauge short wire can carry more current than a same gauge longer wire. 12 – 14 gauge in this application usually is best. Red/Black is for the low beams, and Green/Black is for the high beams. Wires before proceeding…if they are all very confusing IMO, one for headlight! As low as $ 39.99 @ 1Ú2 '' for the male terminal things neatly and properly 86! П‘ I will tighten permanently and improve the spread pattern by keeping all four lights on when in high feed! Pigtail is plenty long enough to reach the headlight wires so I decided to add the using... To tap into before getting started have old light units ) 30 is high. For as low as $ 39.99 disconnected when other accessories are turned on by a small amount of that. 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