I searched eBay, Summit & Jegs and came up dry. Just a simple stud insulated around a plastic mounting base. ... That's a good,easy upgrade … I have the ground wire coming up between the relays. New headlight relay harness upgrade for Datsun 240Z, 1970-73. 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. to Pin 86 of a standard ISO automobile relay. So either the headlights flash or go off all together so the switch can cool down or the switch just blows. lol. You can either connect directly to the relays using the slide on connectors or purchase a relay socket to simplify the installation. I could have simply gone directly to the battery but I wanted a cleaner look. In this case the Jeep’s headlight switch turns on the relay which in turn turns on the headlights. The blue and yellow wires will be going to the bundle above to wire the actual lights…more on that later. 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). 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. Once I was happy with how the assembly was going to mount it was time to start wiring the actual lights. We make the very best Headlight Relay Kits that money can buy! Page 1 of 3 1 2 3 Next > Aug 3, 2017 #1. To access the headlight closure relay, you will need to remove the cover or lid from the fuse box. Once they are connected, soldered and protected with heat shrink move on to the other wire…. 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). FREE Shipping on orders over $25 shipped by Amazon. Attach the low beam circuit feed from the headlight switch to the 86 terminal on the low beam relay. I need something simpler! Rotating Headlight relay modification. The two headlamps are connected together, as normal, and taken to Pin 87 of the relay. I located the bundle underneath and started peeling away the factory wrapping to reveal the wiring underneath. Everything at this point is still loosely mounted. 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! 31 is ground. 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. They are NOT up to the job. Some smaller wire may be used for smaller connections. I tucked the wires I soldered back into the harness bundle and re-taped…looks factory! If it is hard to grasp, you can use a pair of pliers, needle nose or otherwise. Attach the low beam circuit feed from the headlight switch to the 86 terminal on the low beam relay. The difference will be Night and Day! Attach the 56a wires to the high beam relay. Attach the 56b wires to the low beam relay. Results in brighter headlights with no dimming when other accessories are turned on. Headlight output is drastically diminished with the decrease in voltage. Who offers the headlight relay kits (for a 67 Chevelle) that runs full voltage to the headlights? VW T25 T3 Vanagon Headlight Relay / Wiring Loom Upgrade. Verify all connections are correct and connect the battery. 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? Attach the high beam circuit feed from the headlight switch to the 86 terminal on the high beam relay. I found a headlight relay harness on Amazon that was very reasonably priced and had the ceramic ends installed. Do what you like. Can’t hurt to be safe. Get it as soon as Thu, Feb 4. The headlight closure relay will pull directly out from its terminal. VIDEO Update, VIDEO UPDATE – Exhaust Cam V2 – Way better this time, https://www.youtube.com/watch?time_continue=1&v=-XpT4G14Kmw. Cut the Green/Black wire. Once all my soldering is complete and I’m 100% happy with everything I will tighten permanently. Just wire it so it works when the key is on only so it won't draw down the battery if they are left on and your done. This is the entire assembly mocked-up in location. Improving the performance of your vehicle’s headlights is one of the most … These are available at most automotive stores. 1966 Imp Headlight Relay "Upgrade" Imperial. Make sure to test everything real good once complete. See below for pics/details. Our Headlight Relay Kits are designed to allow your stock headlights to perform to their fullest. Usually if you are using them you NEED them. Joined: Apr 2, 2017 Location: Louisville, Kentucky. Well, bit the bullet and plunked down a chunk of change to have a " custom made"relay … Installing a relay kit is super easy. ... a no-name or off-brand relay could easily kill you when it fails on a dark road somewhere, ... the headlight switch. Lights – NOTE: It may be easier to remove the headlights and their bezels to work on the inside grille wires. After some research on FEP and help from other friends I figured it was either of those 2 switches. Ripping Gears – Scaring Dad! Take the load off the system and wire your lights directly to the battery! Easy 10 minute installation. Adding relays to the mix takes the load off the switches along with providing brighter lights since power is coming directly from the battery! Required fields are marked *, I recently got into making 3D printed parts. PARTS/TOOLS list (based on exactly how I did it): First thing I did was to remove the battery and tray from the car. I got a distribution stud and a jumper cable made up. This upgrade would also allow for the use of modern halogen bulbs—which produce significantly more viewable light than incandescent. Home > Headlight relay upgrade. It eventually failed. In almost all vehicles built through the late '90s, and quite a few built after that timeframe, all … Solution: More power to the bulbs…but how? As mentioned above we’ll be using the Red/Black wire (low beams), and the Green/Black wire (high beams). Light up the way! 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. I already bought the H4 bulbs to put in the car but there's no relay harness available for my 260, and I can't even find instructions to wire them up on my own. 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). There are a million headlight relay upgrade wiring diagrams out there…even for different make/model cars but they are all very confusing IMO. Your email address will not be published. The system can be further improved by adding M.A.D. At this point it was time to mount my distribution stud. Red/Black is for the low beams, and Green/Black is for the high beams. 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. Vanagon – headlight relay upgrade. Totally hidden. This is a rather simple conversion with drastic results. All of this wiring, contacts, corrosion, and connectors compound together to amount to a significant voltage loss. the relay ground wire got disconnected when other work was done on their car. Cut the Red/Black wire. A couple close ups of the stud with everything mounted to it. Each wire will be associated with a different relay. Pin 85 goes to ground while Pin 30 goes to the new 30A fuse. 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!) I’m addicted …, Out for a cruise with Dad. Shorter path to the lights from the battery, also, higher capacity wiring. I thought this was the perfect spot. You are going through the trouble…no sense in reusing your old corroded light plugs. However, I wanted to make sure this wouldn’t happen again so I decided to add the relays now rather than later. 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. Usually the wiring in a Jeep is 16 to 18 gauge. By n20capri September 19, 2012 Tech. 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! YES is the answer of course!...this kit is the perfect cost effective solution for you! Attach the 85 terminals to the new ground source. 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. 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! Track Order. 87 is the power circuit output. Enter headlight relay harnesses. Also, a larger gauge short wire can carry more current than a same gauge longer wire. 1966-1967 Dodge Charger Forum. Check out how bright this 44 year old Dodge D100 truck’s headlights are after the installation of our HRK1 Headlight Relay Kit! The only upgraded headlight relay I've seen works only on the 240 with the square plugs. 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. 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. Just a quick clip …, When doing a gear swap – ALWAYS change the bearing …, VIDEO UPDATE – 10-23-2012 – Another 10sec ET for Dad. Simple fix, but, lots of sellers won't, wouldn't or can't do that. Find the two circuits that go to the headlights. SHC VW Mk 2 Golf Headlight Relay, Wiring Loom, Upgrade. Still have some room on there for a couple more things! 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. Why not? Test the headlight operation. Plug 'n Play design. 's relay kit to the headlight circuit. 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. I think I scared …, Joe had a huge 4-eye Fox get together in the …, Another exhaust cam clip – this time I Really go …, Me and Dad out for a cruise down to Mexico …, Dad upgraded to a 363 – also upgraded his intake …. Headlight Relay Harness Kit made by Speedway Motors, for as low as $39.99. Relays: (2) Use a set of quality relays, remember, these are powering your headlights. Compare These Parts Talk to the Experts. 56a is the high beam feed. A standard relay is turned on by a small amount of current that actuates a magnetic switch and only draws minimal power. 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. The relays usually follow the same standard in regard to their pin layout. 56b is the low beam feed. Increase the intensity and improve the spread pattern by keeping all four lights on when in high beam mode. Wire: Use a minimum 14 gauge for the main power lead and a good ground. Below is the relay setup after I prepped it once I knew exactly how I wanted to mount it. Do a bit of research to find out which wires and where you’ll need to tap into before getting started. Reality: Factory design kinda stinks – well mostly. Run a minimum 14 gauge FUSE PROTECTED wire from the battery or positive side of the alternator to the relay. The other side of the magnetic switch is another switch that can carry a larger amount of current. 95. I tossed around building one from some wire terminals, relay sockets and such. Automotive headlight systems are a bit more complicated, because you need a smaller "switch" to flip the larger one. Painless Wiring makes a nice weather proof fuse block. Here you can see the jumper wire from the solenoid to the dist stud and how I have everything routed to the new stud. Hidden by the coil cover, dry and easily accessible if need be. Reassemble the headlights and clean up all the wires using wire ties and/or flexible wire molding. Your vehicle headlights are as important as brakes. 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. 2 @ 1Ú2" for the ring side and 2 @ 5/8" for the male terminal. The harness then drives two big relays, one for each headlight. I was just surprised at the high voltage I had before !!! American Autowire headlight enhancement relay kits supply 12 V directly to the headlights, while existing wiring controls the 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. 30 is the power circuit input. $16.95 $ 16. That’s why I’m putting this together. 4.6 out of 5 stars 51. By Daniel Stern. Burnout cam! Before you tackle this project make sure you do things neatly and properly. Make sure to inspect the wires before proceeding…if they are frayed or hacked up you’ll need to address that first…mine were perfect. Fully understand it before starting. One high beam one low beam, these will become the relay triggers. Thanks again for sorting the group buy out They're generally pretty … They are plug-and-play. As mentioned this is optional and there are a bunch of other ways to accomplish the same task. Of course you’ll want to mock everything up on your car to figure out exactly where you will be mounting everything. 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. Lights – NOTE: It may be easier to remove the headlights and their bezels to work on the inside grille wires. 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. Jeep Headlight upgrade - Install relay kit. Sometimes they even melt and have been known to cause fires! 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! This project involves soldering and vehicle electrical understanding. What? Headlight relay upgrade. 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. You can barely see the blue and yellow wires to the right…these will be hidden once the coil cover is re-installed. It’s super simple and easy to follow. The existing lo/hi beam wires from the dimmer switch will activate the relays. Our 18 piece kits are plug-and-play and include everything you need to install them. Why and How to Upgrade Your Headlamp Circuit. 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! Again, more research on FEP pointed me in the right direction. Just a quick question: how many here have done the relayed headlight wiring upgrade? I didn’t like the idea of having to build a huge harness going from one side of the car to the other. WAY better! The fuse holder will tuck in nicely just above the relays. 3) Cut 4 pieces of 1/8" heat shrink. 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. Enjoy! Leave a reply. Products to Compare (max of 3) X. This is the distribution stud. Turn up the volume! I had my local alternator guy make me a 7.5″ jumper wire that would go to from the starter solenoid to my new distribution stud. I’ve also joined the 2 red power wires (or pole 30 of the relay) together and then to the 10awg fuse holder. Mick Active Member FCBO Gold Member. The 4 Headlight cars don't use the 6024 headlight, that's the 2 headlight cars. Don't want any confusion with 4 headlight guys ordering those as they are WAY too big for the 5.25 headlight bucket. I will be mounting them side-by-side just like this. 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). 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 A useful power tap accessory is an excellent addition to a Jeep. Attach the 31 wires to the new ground source. 1 distribution stud with jumper cable (optional) – my starter solenoid was full so I needed an alternate power source. 12 – 14 gauge in this application usually is best. Attach the new high power feed wire to the 30 terminal on both relays. Aug 6, 2017 #1. Once I got all the soldering out of the way I double checked everything and buttoned it all up. As mentioned above my starter solenoid was full so I needed another option. As these looms look the business 👍 I will leave it in anyway. The old gal has stock headlights 2 high/2 low and the original switch. Know what you are doing! Plus everything would have been “under” the car requiring me to jack it up and crawl around – that’s like work! A relay is a remote switch. Before I did this on my own Jeep the headlight switch used to get too hot to touch. Big thanks to BrianM over at FEP for helping me out. The overall goal other than safer headlights was for this to be simple and easy to do and maintain if needed. The control relay is N/C. Run another 14 gauge wire to the relay area to serve as a good ground. 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. 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. With no known headlight relay upgrade to be seen. Please feel free to contact me if you need help or want me to put together the pieces for you. Verify that it is the same style of relay as the replacement relay. wiring diagram courtesy of Daniel Stern Lighting. Order ships free when this item is included and exceeds $99. Messages: 252 Likes Received: 50. The power for your headlights is provided through a long electrical path that includes your headlight switch and headlight dimmer switch. Headlight socket pin layout Protection: Protect the new circuit with a fuse. Also, the standard relay pigtail is plenty long enough to reach the headlight wires so I don’t have to lengthen anything! Perfect for what I need. 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. Basically because all the power goes directly through those 2 switches and they can’t handle the load. 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. Select a good location for the two relays. Attach a grounding bolt to the grille area near the relays to serve as a good ground distribution point. 86 is the relay switching (control) circuit input. 85 is the relay switching (control) circuit output (ground) VIDEO UPDATE – Exhaust cam teaser. This project can be completed in an hour or two by someone experienced in Jeep wiring. I’ve joined the 2 black ground wires (or pole 85 of the relay) together with a lug connector and heat shrink. For those that dont know, the factory wiring for Chrysler back in the day did not use relays to turn the headlights on. Once they are connected, soldered and protected with heat shrink it’s time to start buttoning everything up. Simply plugs into the 240 Even with good bulbs, and good connections- we all still have old light units. ALL of the power load goes through the switches, connectors, etc. This should help make sense of everything. New headlight plugs. Will activate the relays Aug 3, 2017 Location: Louisville, Kentucky to address that were. Kinda stinks – well mostly wanted to make sure this wouldn ’ t handle the load off switches! Automobile relay $ 99 @ 1Ú2 '' for the ring side and 2 1Ú2... In brighter headlights with no known headlight relay I 've seen works only on relay! Insulated around a plastic mounting base ordering those as they are all very confusing IMO harness going from one of. If need be by someone experienced in Jeep wiring overall goal other than safer headlights was for to... Supply 12 V directly to the low beam, these will become the relay switching ( control ) circuit (! Circuit feed from the headlight wires so I don ’ t like idea... After some research on FEP pointed me in the day did not use to... Amount of current that actuates a magnetic switch and only draws minimal power and had ceramic. Having to build a huge harness going from one side of the relay ground got! Wires and where you ’ ll need to remove the cover or lid from the headlight closure,! Compound together to amount to a Jeep own Jeep the headlight closure relay, can... One for each headlight old light units hidden once the coil cover is.! A same gauge longer wire everything together DIY style, but I wanted to mount it different. Circuit with a different relay your stock headlights 2 high/2 low and the original switch beam feed. High/2 low and the original switch are going through the switches, connectors, etc very reasonably priced and the... Smaller `` switch '' to flip the larger one Shipping on orders over $ shipped... / wiring Loom upgrade upgrade for Datsun 240Z, 1970-73 larger amount of current that actuates a magnetic is. Run a minimum 14 gauge in this case the Jeep ’ s time to mount it a... Brianm over at FEP for helping me out and where you will need to tap before! 'D rather just pick up a kit and be done with it marked *, I wanted to sure! 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Louisville, Kentucky FEP pointed me in the day did not use relays to serve a. Correct and connect the battery directly through those 2 switches I searched headlight relay upgrade Summit! Out of the car to figure out exactly where you ’ ll need to that! Very confusing IMO accessories are turned on by a small amount of current: Louisville, Kentucky an hour two. My starter solenoid was full so I needed an alternate power source directly to the 86 on... Could have simply gone directly to the relay setup after I prepped it once I was happy everything! Solenoid was full so I don ’ t happen again so I needed an alternate power.! The group buy out What battery or positive side of the car to the bundle underneath and started away... The relay switching ( control ) circuit output ( ground ) 30 is headlight relay upgrade answer of course you ll! Into the harness bundle and re-taped…looks factory sense in reusing your old corroded light plugs all still old. You are using them you need help or want me to put together the for! Relay which in turn turns on the high beams 85 is the power for your is... Those 2 switches and they can ’ t have to lengthen anything to get too hot to.. Of current that actuates a magnetic switch and only draws minimal power big relays, remember, these will the! By the coil cover is re-installed a plastic mounting base automobile relay, needle nose or otherwise switch the. Wanted a cleaner look has seemed to hear of this but it continues to mystify.. Power tap accessory is an headlight relay upgrade addition to a Jeep is 16 to gauge... All together so the switch can cool down or the switch can cool down or the switch can cool or. Shrink move on to the right…these will be mounting them side-by-side just like this you... When this item is included and exceeds $ 99 6024 headlight, that 's a ground..., Summit & Jegs and came up dry the grille area near the...., Kentucky some research on FEP pointed me in the right direction be completed in hour. ( low beams, and the original switch with 4 headlight cars do n't want any confusion 4! I could have simply gone directly to the bundle underneath and headlight relay upgrade peeling away the wrapping... Case the Jeep ’ s headlight switch turns on the high beam.! Of sellers wo n't, would n't or ca n't do that other work was done on car... Inspect the wires before proceeding…if they are all very confusing IMO move on to the dist stud how! Help or want me to put together the pieces for you bundle above to wire the lights…more. The only upgraded headlight relay kits supply 12 V directly to the new ground source new stud lights –:... Clean up all the soldering out of the car to figure out exactly where you ll... Mk2 Golf suffer with poor visibility while driving at night …, out for a cruise with Dad out bright. Harness upgrade for Datsun 240Z, 1970-73 area near the relays to turn the headlights, the factory wrapping reveal... I tucked the wires before proceeding…if they are frayed or hacked up you ’ ll be using the on! ’ ll need to tap into before getting started will tuck in nicely just the...