DIY headlight wiring harness upgrade for low $$
#101
#102
bumping this thread, I'm in the process of building my harness, need the resitors and some better diodes... I will add my results, not sure what schematics I will be robbing yet...
just wanted to also mention x2 on DelCity.net being a GREAT place to shop, I ordered like $300 worth of wiring, relays, connectors, fuse boxes, switches, wire loom, pwr sockets, etc... all their stuff I got was exactly what I saw online and very pleased with their products and customer service. I even got a christmas card! they have some rockin' deals, but like said, watch the minimum order, i think it's $99?. this is a good place to stock up for future projects. I don't have to run to town now for a stupid relay or switch now for my random 'upgrade' projects...
Glad I found this thread in time, thanks fellas for the good write-ups!
just wanted to also mention x2 on DelCity.net being a GREAT place to shop, I ordered like $300 worth of wiring, relays, connectors, fuse boxes, switches, wire loom, pwr sockets, etc... all their stuff I got was exactly what I saw online and very pleased with their products and customer service. I even got a christmas card! they have some rockin' deals, but like said, watch the minimum order, i think it's $99?. this is a good place to stock up for future projects. I don't have to run to town now for a stupid relay or switch now for my random 'upgrade' projects...
Glad I found this thread in time, thanks fellas for the good write-ups!
#103
I tried these drawings for hours yesterday. They all resulted in low beams on with high.
I ended up using two relays in series. One triggered from low beam feeding through the other. The second relay output switches from low beam(unpowered) to high beam(on). Now drawing about 9 amps with both headlights on low or high beam. No indicator light yet.
I thought I would pass this on. I kept reading about how easy it should be to make a harness but it turned out completely frustrating. Unless you want the low beams on with high, then it would be easy. I don't want to melt anything or wreck the reflector.
'98 runner is what I was working on. Maybe the drawings work with different generations?
I ended up using two relays in series. One triggered from low beam feeding through the other. The second relay output switches from low beam(unpowered) to high beam(on). Now drawing about 9 amps with both headlights on low or high beam. No indicator light yet.
I thought I would pass this on. I kept reading about how easy it should be to make a harness but it turned out completely frustrating. Unless you want the low beams on with high, then it would be easy. I don't want to melt anything or wreck the reflector.
'98 runner is what I was working on. Maybe the drawings work with different generations?
#104
yeah, we already figured it out. it's because when you turn the high beams on, stock, there is electricity flowing through the high beam indication light. there is enough current to light the indicator, but not the low beams. when you put a relay in, the current becomes sufficient to activate the low-beam relay.
#106
#107
Never thought of it that way, come to think of it our e34 is the same way, but it's also a 4 light system and not a 2. Doubt I'd ever be puled over for it, cus yur not supposed to have the high beams on that close to traffic anyway.
#109
ok so im lost.
trying to wire up 2 h4 style headlights with a kit from headlightservices.com
it came with 2 5 pin relays and all the connectors.
the instructions it came with are for a switched power style .
but from as far aas i can tell its wired up the same as xxxtreme22r describes with the ground wire on the old headlight plug going into pin 85 on relays
like this
and ive seen a few people recommend this page for directions http://www.go.jeep-xj.info/HowtoHeadlightLoom.htm ( but im assuming i wire the grounds on relays to old ground on stock headlight plug ?) and leave everything the same...
so my question is : is their a diagram that i can go off of with the dual 87 plugs or is my first picture the correct setup and if not what do i need to change ?
trying to wire up 2 h4 style headlights with a kit from headlightservices.com
it came with 2 5 pin relays and all the connectors.
the instructions it came with are for a switched power style .

but from as far aas i can tell its wired up the same as xxxtreme22r describes with the ground wire on the old headlight plug going into pin 85 on relays
like this

and ive seen a few people recommend this page for directions http://www.go.jeep-xj.info/HowtoHeadlightLoom.htm ( but im assuming i wire the grounds on relays to old ground on stock headlight plug ?) and leave everything the same...
so my question is : is their a diagram that i can go off of with the dual 87 plugs or is my first picture the correct setup and if not what do i need to change ?
#111
Thread resurrection!!! 
so i bought headlights from that guy on ebay, installed them and the first night running them the drivers side was extremely dim, next night it was completely out. im assuming this is a wiring problem...i have all the materials to upgrade the wiring so
the questions: will the wiring upgrade fix this issue? or is the issue further back in the stock wiring?
BTW im running H4s 90/100w
TIA
Jordan

so i bought headlights from that guy on ebay, installed them and the first night running them the drivers side was extremely dim, next night it was completely out. im assuming this is a wiring problem...i have all the materials to upgrade the wiring so
the questions: will the wiring upgrade fix this issue? or is the issue further back in the stock wiring?
BTW im running H4s 90/100w
TIA
Jordan
#112
Those bulbs are way too powerful for the stock wiring. You will definitely want to upgrade your harness before running anything over stock. Hopefully you didnt do any damage. Also its a good idea to ditch the autopal bulbs and get a name brand like hella or PIAA
#113
the autopal bulb was toast when i pulled it.
i wired everything up per the schematics found in this thread that worked but my lights do not work. which stock headlight socket am I supposed to tap into? driver side or passenger side? i have it hooked up to the passenger side socket but it isnt working correctly. either only the highs work or only the lows work.
oh and i picked up some "xtravision" bulbs until i can get the wiring figured out and feel safe putting some higher wattage bulbs in.
i wired everything up per the schematics found in this thread that worked but my lights do not work. which stock headlight socket am I supposed to tap into? driver side or passenger side? i have it hooked up to the passenger side socket but it isnt working correctly. either only the highs work or only the lows work.
oh and i picked up some "xtravision" bulbs until i can get the wiring figured out and feel safe putting some higher wattage bulbs in.
#115
Definitely don't use the Autopal bulbs. I made that mistake...not 5 minutes of use and the driver's side exploded:

Compared to:

After some negotiating with Rishi/Autopal, they're sending me a replacement housing.

Compared to:

After some negotiating with Rishi/Autopal, they're sending me a replacement housing.
Last edited by BMcEL; Feb 23, 2012 at 11:54 AM.
#116
the autopal bulb was toast when i pulled it.
i wired everything up per the schematics found in this thread that worked but my lights do not work. which stock headlight socket am I supposed to tap into? driver side or passenger side? i have it hooked up to the passenger side socket but it isnt working correctly. either only the highs work or only the lows work.
oh and i picked up some "xtravision" bulbs until i can get the wiring figured out and feel safe putting some higher wattage bulbs in.
i wired everything up per the schematics found in this thread that worked but my lights do not work. which stock headlight socket am I supposed to tap into? driver side or passenger side? i have it hooked up to the passenger side socket but it isnt working correctly. either only the highs work or only the lows work.
oh and i picked up some "xtravision" bulbs until i can get the wiring figured out and feel safe putting some higher wattage bulbs in.
Last edited by aviator; Feb 23, 2012 at 12:08 PM.
#117
Somehow my highs and lows stay on at the same time. How, I don't know, it was a complete accident. But I have yet to blow a bulb because of it. And I use my highs quite a bit. I did blow a set of Sylvania Ultra sealed beams before, but I think that was because of a bad alt coupled with mud in the light sockets. These cheapo GE sealed beams have been good so far. Not the best light output, but I haven't blown them yet.
Last edited by xxxtreme22r; Feb 23, 2012 at 12:11 PM.
#118
the autopal bulb was toast when i pulled it.
i wired everything up per the schematics found in this thread that worked but my lights do not work. which stock headlight socket am I supposed to tap into? driver side or passenger side? i have it hooked up to the passenger side socket but it isnt working correctly. either only the highs work or only the lows work.
oh and i picked up some "xtravision" bulbs until i can get the wiring figured out and feel safe putting some higher wattage bulbs in.
i wired everything up per the schematics found in this thread that worked but my lights do not work. which stock headlight socket am I supposed to tap into? driver side or passenger side? i have it hooked up to the passenger side socket but it isnt working correctly. either only the highs work or only the lows work.
oh and i picked up some "xtravision" bulbs until i can get the wiring figured out and feel safe putting some higher wattage bulbs in.
I would think both sockets would be the same. One of the wires should be the +, and that should go to both relays. Those pictures are just general ideas, not toyota specific examples. I got mine working similar to this http://www.ih8mud.com/tech/headlightharness/diagram.pdf but without the top left relay because we don't have that extra set of lights.
#119
Thread resurrection...hey I appreciate all our help in advance. I followed this diagram exactly http://i561.photobucket.com/albums/s...eadlights2.png (exept no diode) in a 92 pickup. I have h4 hella vision plus conversion, I get brights all the time. I took apart the combo switch which looked super clean inside, and cleaned the connectors anyway with emery board and got off some carbon.
I get constant 12.5v at the common connector and get .04-.03v on the high bean and the low beam no matter what the position is. The weirder thing is that when I plug in the other plug on the old sealed beam into the old harness, it does do high and low, and then sometimes does both together. which to me suggests the combo switch is messed up. I've heard talk of something called a sheild that can get fried in the combo switch.
The common connector just gets capped right?
Anything is appreciated
I get constant 12.5v at the common connector and get .04-.03v on the high bean and the low beam no matter what the position is. The weirder thing is that when I plug in the other plug on the old sealed beam into the old harness, it does do high and low, and then sometimes does both together. which to me suggests the combo switch is messed up. I've heard talk of something called a sheild that can get fried in the combo switch.
The common connector just gets capped right?
Anything is appreciated
Last edited by wierdobsession; Mar 7, 2012 at 08:57 PM.




