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Brighten Your Lights - Installing Headlight Relays

-page 2-
some information provided by Daniel Stern Lighting
 

Installation:

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. 

 

Diagram: click for larger image

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 layouts

86 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.

Headlight socket pin layout

56a is the high beam feed.
56b is the low beam feed.
31 is ground

Following the above diagram...

Relays

  • Attach the high beam circuit feed from the headlight switch to the 86 terminal on the high beam relay. 
  • Attach the low beam circuit feed from the headlight switch to the 86 terminal on the low beam relay.
  • Attach the new high power feed wire to the 30 terminal on both relays.
  • Attach the 85 terminals to the new ground source.

Lights - NOTE:  It may be easier to remove the headlights and their bezels to work on the inside grille wires.

  • Attach the 56a wires to the high beam relay.
  • Attach the 56b wires to the low beam relay.
  • Attach the 31 wires to the new ground source.


Finished Relays

Verify all connections are correct and connect the battery.  Test the headlight operation.  Reassemble the headlights and clean up all the wires using wire ties and/or flexible wire molding.  This project can be completed in an hour or two by someone experienced in Jeep wiring.

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