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Unread 09-08-2011, 07:04 PM   #16
Reptile
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1991 XJ Cherokee 
 
Join Date: Feb 2011
Location: Bakersfield, CA
Posts: 1,297
Quote:
Originally Posted by RacerX View Post
This is pretty much the same as mine, mine looks cleaner because I've replaced some stuff, and cleaned up the wiring (been working on the wiring for YEARS now) put new breakers in and added a extra line to the headlights with 30 or I think 40 amp breaker.
You battery cables do show some signs of corrosion; looks to me like the insolation on your ground cable is compromised and exposing the wire. Also your ground is not connected to the frame it looks like. You can find a wire brush to clean your battery posts and leave them shiny looking good. Might use some baking soda on the battery connectors.

Get rid of that Fram filter... That's what you get for exposing some naked pix of your XJ

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Unread 09-08-2011, 07:20 PM   #17
Flyordie
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1985 XJ Cherokee 
 
Join Date: Dec 2009
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Posts: 738
Yes, dump the FRAM!

As for the battery stuff, yea.. I'd clean up them cables a bit. Corrosion sucks and hurts the connection badly.
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Unread 09-14-2011, 06:09 PM   #18
RacerX
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1989 XJ Cherokee 
 
Join Date: May 2010
Location: Snohomish, Washington
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Quote:
Originally Posted by Reptile View Post
You battery cables do show some signs of corrosion; looks to me like the insulation on your ground cable is compromised and exposing the wire. Also your ground is not connected to the frame it looks like. You can find a wire brush to clean your battery posts and leave them shiny looking good. Might use some baking soda on the battery connectors.

Get rid of that Fram filter... That's what you get for exposing some naked pix of your XJ
LOL.....

No that's NOT my XJ, just same year - I didn't have time to take and post a pic.

I still need to clean up the Pos cables a little. I also want to replace all the fuse-able links with breakers - I hate fuse-able links! It's cheap crappy solution.
p1050665-batt-comp.jpg  
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Unread 09-19-2011, 03:34 PM   #19
RacerX
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1989 XJ Cherokee 
 
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Originally Posted by Flyordie View Post
Yes, dump the FRAM!

As for the battery stuff, yea.. I'd clean up them cables a bit. Corrosion sucks and hurts the connection badly.
So,.. What's with Fram filters, anyway?
What kind do you use, recommend?
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4-wheeling is about going where others can't won't or don't think it's safe.
Freedom. Exploring the wilderness, or nature, whatever... - NOT paying to go on someone's roller-coaster ride, or go-cart track!
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Unread 12-19-2011, 03:04 PM   #20
waffalz
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1991 XJ Cherokee 
 
Join Date: Sep 2011
Location: reidsville, North Carolina
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Hey guys ok so my switch was smoking and I lost all tailights/gauge lights so I opened up my dash and the orange and blk wire is melted what does this mean need answers ASAP !!!!!!!!
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Unread 12-19-2011, 04:56 PM   #21
Azzy
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Skip looking into LEDs. They cant throw enough light, and if they can, you can buy a new XJ with the amount they cost.

LED costs for headlamps are so bad BMW started looking into lasers as a cheaper solution.. laser light diffused by phosphor coatings to scatter the light.

And properly aimed and setup lights wont blind people.
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Unread 12-19-2011, 05:38 PM   #22
cold_steel
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Man this headlight system is the most jacked up junk I have ever seen. I cannot believe with all these gear heads and smart people on here there is no clear cut thread on how to resolve this headlight issue.
I mean its wires burning!!! That is amatuer hour, what electrical engineer is designing this.
I read a thread about the fan motor melting wires. What the hell were they thinking?
This is crazy...
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Unread 12-19-2011, 06:41 PM   #23
RacerX
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1989 XJ Cherokee 
 
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Originally Posted by waffalz View Post
Hey guys ok so my switch was smoking and I lost all tailights/gauge lights so I opened up my dash and the orange and blk wire is melted what does this mean need answers ASAP !!!!!!!!
It means the the headlight Power draw (or/and other lights) over-heated the wires to the point that the insulation melted and since the wires sit next to each other they shorted.

You will prob need to replace the wires at least up to where the short is.
If you turn the lights on now it will prob get worse, unless you burned a fusable link - check them, near batt at the main power relay

I replaced the switch with toggles (and have indicator lights so I can tell with a glance which lights are on - day or night)
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4-wheeling is about going where others can't won't or don't think it's safe.
Freedom. Exploring the wilderness, or nature, whatever... - NOT paying to go on someone's roller-coaster ride, or go-cart track!
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Unread 12-21-2011, 07:34 AM   #24
waffalz
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Thanks man
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Unread 08-08-2012, 05:00 AM   #25
RacerX
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1989 XJ Cherokee 
 
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Location: Snohomish, Washington
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Quote:
Originally Posted by Azzy View Post
Skip looking into LEDs. They cant throw enough light, and if they can, you can buy a new XJ with the amount they cost.

LED costs for headlamps are so bad BMW started looking into lasers as a cheaper solution.. laser light diffused by phosphor coatings to scatter the light.

And properly aimed and setup lights wont blind people.
$500 for set of LED 5x7" Headlamps

http://www.4wd.com/Jeep-Lighting-Jee..._pn=POI27450CK

Oh, and BTW, your headlights are the best RADAR reflector ! (another reason I wanted to go LED, but just a flat panel full of LEDs)
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4-wheeling is about going where others can't won't or don't think it's safe.
Freedom. Exploring the wilderness, or nature, whatever... - NOT paying to go on someone's roller-coaster ride, or go-cart track!
"The price of freedom is eternal vigilance." - Thomas Jefferson
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Unread 08-08-2012, 08:03 AM   #26
tonytwotimes
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Was anything else spliced into the headlight circuit? LIke are their any electrical components that don't work if you don't have your headlights on or any little piggy tails comming of the hot side?

I ask because people seem to be so smitten by running every aux componrent they can on the headlight circuit. I just bought an 88 cherokee that had almost the exact same issue. The dash was ripped completely out and he said I was gonna have to re wire the whole jeep. Turns out, he had a winch, stereo amp, and stereo head all worked into the hot wire right behind the dimmer switch.

I went to the junkyard and cut the harness back as far as i could under the dash in an old xj and then stopped at auto zone for a new switch on the way home. A few new fuses, and the good ol' smell check and now all my lights work.

Sadly, this is not the first time I had dealt with an issue like this. I once turned the heater on in an 85 Ram I had while driving down the freeway at night. Suddenly it was very dark and very cold. Toggle switch heater directly into the drivers side headlight socket.
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