So I wanted to wire up my fog lights on my bumper, but I had to fab up a panel to hold my switch(s) so that took up alot of my time, I layed out my wires, I connected the ground and power wires inside the lights, sealed them back up. I bolted my relay up, I ran my wires to my lights and my switch.
I grounded my switch, and my relay. Now here is where it gets funky..

I had to splice the wire going from my switch to the battery since they wanted me to attach it to my high beam wire, but since I wanted it to be able to turn off and on when I want I wanted to run it to the battery. I spliced in some 16 gauge wire I had left over from wiring my tractor lights.
I had my lights grounded to my light bar.

I turned on the switch and I go look at the lights. Okay my drivers side is on, I fiddled with the bolt that I have my ground wires against, I get a spark and my light slowly dims till its off.. dammit!!

So by that time it was dark so I had to put my dash back together.

now this morning I went to the parts store, got a length of 16 guage blue wire so I can extend my grounds from my lights to inside the engine bay.
I splice the two light grounds together then attach that to my new wire.
I then ground it where all my other grounds are.

Still nothing.. so I switch to my other switch... nothing.. I finally wire in the switch hella sent with the kit.. still nothing!!

Im so lost right now.. Any of you guys have any ideas?

 

Maybe test your bulbs... make sure they work outside of the Hella casing.

Make sure you have 12V with a voltmeter with the switch on, and nothing when off.

Double check any related fuses as well.

 

I will pull the bulbs back out tomorrow if I get a chance ( its raining, and I can't use the garage) and I guess I will go buy a voltmeter too.

Any other suggestions? I had a feeling it was to do with the wires I spliced in to extend the stock wiring. What guage are the wires they give you?

 

OK I am guessing these are brand new lights, and you stated that you want to turn them on independent of the high beams. starting at the light your power wire should connect to the relay, and from the relay to the battery through a fuse, ground the lights to the body or frame. Now for turning them on and off, run a power wire from the battery to the switch in the cab, and from the switch to the relay, and ground the other side of the relay to a good ground, you will also want to ground the switch if it has a indicator light built in. when I ground my lights I usually will ground each one seperatelly so if i have a problem with one I don't have to trouble shoot both lights

 

I have it set up like so.

Main power from battery, to fuse, to relay
Wire from relay to lights
Lights grounded onto inner fender
Relay grounded onto inner fender (same bolt)
wire from relay to switch
wire from switch to battery
switch grounded

I have gone over the instructions 20 times and I have everything hooked up the same except for my wire going to the battery so its hot, and my light grounds attached to one wire that is grounded..

I hope I didnt fry anything when I tested them out with improper grounds..

 

do you have the right connections at the relay?

pin 30 should come straight from the battery and be fused

pin 87 goes to the lights

pin 85 and 86 is the power and ground from the switch it doesn't matter which one is which, for instance 85 can be hooked up to your switch and 86 grounded

 

Yes all pins are correct.

My switch lights up too.

 

I would check my connections and make sure I didn't brake something, I am good at screwing up crimp connectors. Do you have other accessories at the same grounds, and do they work well? How about the relay a simple thing to do is pull off the wire from the relay to the lights and touch it to the battery post, if the lights come on try replacing the relay. let us know

 

I have my tractor lights relay gounded to the same ground, they work great.

I will try pulling the light wire and putting it to the battery after dinner

 

Okay, I pulled the lights wire off the relay, and touched it to the + battery post. I made a spark but the lights didnt go on..

The wire for the lights was send to me from hella with a connector joining the 2 wires so it could plug into the relay. All I had to do was put a crimp connector on the end so it could plug into the light....

This is horrible, the tractor lights where easier to wire and I didnt have any instructions!

 

I don't know if this will help you any. http://4runners.org/writeups/hella500/index.html

 

Thats pretty much exactly what I did, but I put my green wire right onto my battery.

 

Also...

That from the link you posted, my hella instructions have it like....

RELAY..........other connector..
30....red fused link to batter
85....yellow wire to switch
86....ground
87.... duel black wires to lights

 

Sounds like a short between the relay and the lights, or possibly in the lights. How did the bulbs test?

 

I havnt tested the bulbs, I was thinking of just unbolting the fog light and using the set of driving lights as a tester, to see if I blew both of the fog bulbs. sound good?

 

OKay, I undid the fog lights, took them out of the cover and then touched the black wire to the black wire and the blue wire to the blue wire on my driving light.. Nothing.

Im losing my brain here guys!!

*edit* well its now too dark to work on them today DOH!
Monday I have school and then a night class. So I doubt I will be able to do anything on the truck. BUT I need more ideas guys, I am so lost here its incredible.

The lights didnt turn on when I bypassed the relay and touched the light wire right to the battery, it just sparked. What does that mean?

 

Take a breath, all of your other accessories work, so lets figure this out. put in a bulb that you know works if no light start checking wires. You said you have driving lights that do work are they wired the same way?

 

Well I have a set of driving lights, brand spankin new. I have to wire them up next (on the roll bar) but I have to pull the roll bar out to drill more holes so I wanted to do the fogs first.

so far things I know are good:

Wires from lights to relay
wire from battery to relay
Wire from relay to switch
Wire from battery to switch (switch lights up properly)

Things im not too sure of:

Relay- people are saying it should *click* it might be clicking but it might not. I swapped in a different relay and it didnt make a difference.
Lights themselves
grounds - even though Im grounding them to the same spot as my tractor lights relay.

 

It is tough to hear the relay click from the cab if you take a short length of wire and connect it to the battery and touch it to the switch pin on the relay you should here the click.
You said the light in the switch comes on, this tells me you are getting power to the switch, how about back out to the relay? This can be tested with a small light up tester.
I am thinking that your ground is in a good spot since your tractor lights work.
Where is the relay grounded to?

The order of things I would check next time you can work on it; bulbs, fuses, wire between switch and relay, relay itself,

Good luck

 

I will test the relay tomorrow with wire from the battery to the switch post on the relay.

How do I test the bulbs?

The fuse is good, I pulled it out, lose it in the engine bay so I snagged the one from my driving light kit.

Relay and lights are grounded to the same place my tractor lights are.