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Unread 10-23-2009, 02:03 PM   #1
racerx8413
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Headlight Switch Wiring

Can anyone provide a picture or diagram of the headlight switch wiring?

I'm in the middle of changing the YJ Dash to CJ,
http://www.jeepforum.com/forum/f12/m...-build-884356/

And am about to that step.

I have this switch,
Headlight Switch*5450558 by the Jeep Specialists | Morris 4x4 Center

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Unread 10-23-2009, 02:13 PM   #2
John Strenk
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Are nyou using a YJ harness or starting from scratch?

Here is a little info I cooked up for CJ's
Quote:
Did you know that there were 2 light switches for CJ's? To bad quad and 4WD only sells one. [update] They sell both now[/update]


Because of this I've been doing a little more investigation into this Lighting stuff.
THe basic problem is the way that the light switches connect to the fuse box.
There are actually 3 fuses involved with this switch.
Early CJ light switches hook up this way: 76-77 for example.


Notice the orange wire. This connects to a plug....Someplace, probably the harnes for the courtesy lights. In this case power for this connection has to come from the main headlight source. That is why there is a jumper on these switches.
Here an 82 CJ light plug:


On the 82 CJ, This wire is now White wire comes from the fuse box were there is a fuse supplying power for the parking lights. (and panel lights)
Here is a closeup of an 82 fuse box schematic

You can see what fuses are involved.
But before you go blind tracing out the runs. I put together a collage of prints and show how the wires run in an 82 and later light circuit. Not all lights are covered.

White wires do not come out wery well so I made the white wires blue.
As you can see there are 3 fuses involved.
1 20 Amp fuse for the tail lights and parking lights
1 15 amp fuse for the Dome-Courtesy lights
1 3 amp fuse for the dash lights.
Make sure you inspect all 3 fuses when troubleshooting lighting problems.
Basically power from a fusable link connected to the battery connects the the 15 and 20 amp fuses and then to the light switch. This is the main source of power to the head lights.
Power for the parking lights travel thru the 20 amp fuse to the switch. Inside the switch is a jumper that connects this circuit to the wiper for dimming the panel lights. This jumper is indicated with the dotted yellow line in the picture.
When the switch is in the Park or headlight position the power then goes thru the switch out to the tail lights and parking lamps. obviously if this fuse is blown then you would not have BOTH parking lights or Panel lights. If you did out in an old style switch with the extra jumper it would then start working even though the fuse if blown.
The power also travels thru the wiper on the dimmer back to the fuse box thru the 3 amp fuse. and then to the panel lights . Pretty convoluted huh.
It even more interesting that the dome or coutesy lights get it power, in this case, directly from the 15 amp fuse in the fuse box. THe power then travels thru the dome light back to the light switch were it is GROUNDED by the light switch. This leads us to make sure the light switch is properly grounded also or your dome light won't turn on with the light switch.
Ever wonder what is inside?

Picture tells the story. Notice the circuit breaker for the headlights and the grounding tab for the dome lights.
Here is what the knob plugs into:

Notice the "V" shapped opening? This is what moves when you press the little button to release the shaft. Notice also the two sets of contacts.
Here is how they work:

One last thing, here is the back of the fuse box if you ever have to pull it out to check your lights.
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Unread 10-23-2009, 02:15 PM   #3
racerx8413
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Ha, ask and you shall receive :P Thanks man! I'm working off of a YJ Harness, it will be cut.
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Unread 10-23-2009, 02:17 PM   #4
John Strenk
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Here is a schematic I highlited later:
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Unread 10-23-2009, 02:24 PM   #5
John Strenk
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But this is probably what you wanted:


I think this is for a 76 CJ but I'm showing a later model switch

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Unread 10-23-2009, 02:30 PM   #6
John Strenk
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Also, If the YJ headlights are not set up with a relay, then add that to the circuit and you will find the switches last much longer. How are you hooking up a headlight dimmer? Using a floor switrch or the YJ column dimmer?
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Unread 10-23-2009, 02:33 PM   #7
racerx8413
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That's rediculously helpful Maybe you can tell me why only the passenger side front park light blinks, and when i put on my left parking light, my stereo blinks on and off! LOL.

Going to examine this issue when I start putting things back together
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Unread 10-23-2009, 02:37 PM   #8
John Strenk
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Thats simple One of your lights are not grounded properly and backfeeds through the radio lights. Elctrisity is always looking for a good ground even if it has to go through the most unexpected route. CJ turn signal lights grounf through a special screw with a long shoulder that is suppose to ground the socket to the grill. If you don't use this screw then you might not be able to make a good ground. I drilled a hole in my reflector and put on a terminal so I can ground it independently of the screws.
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Unread 10-23-2009, 02:42 PM   #9
John Strenk
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Buy the way, there is a guy on htis forum that probably can make you the angled gauge rings you need to move the gauges out a little in your dash.
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Unread 10-23-2009, 03:15 PM   #10
racerx8413
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Quote:
Originally Posted by John Strenk View Post
Also, If the YJ headlights are not set up with a relay, then add that to the circuit and you will find the switches last much longer. How are you hooking up a headlight dimmer? Using a floor switrch or the YJ column dimmer?
I intend to use the column dimmer, as well as the wiper controls on the column.

Essentially, for the headlight switch, I only care about Off, Park Lights, and Headlights.

thanks so much for this help John,

According to the switch diagram, I could run my dash light + power directly from the headlight switch?
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Unread 10-23-2009, 03:28 PM   #11
John Strenk
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Yep. and the dimmer would work this way.

Note the dash lights should have an inline fuse installed going to the dash lights from the switch. The CJ fuse box has one but not sure if the YJ box is set up the same way.

It's almost as if the CJ engineers expected the dash lights to short out....
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Unread 10-23-2009, 03:36 PM   #12
racerx8413
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I plan on inline fusing everything under the dash.

The dash lights, all a single circuit, I'll stick it between the headlight switch and the first dash lamp (headlights)

The Ignition On (yellow wire) will have the inline fuse inline before the quick disconnect plug I'm wiring in.

I wouldn't mind installing a quick disconnect to the headlight switch, and the fan speed switch either.

Essentially, when I go to bolt this dash in, I will only have the following to plug in.

Speedometer cable
Quick disconnect for ignition on and ground,
Quick disconnect for sending 4 gauge sending units
Quick disconnect for turn signal indicators and high beam indicator
(Future) Quick disconnect for headlight switch
(Future) Quick disconnect for fan speed switch
3 Vent control knobs and cables



I'm using the connectors typically found inside computers, the flat 4 wire power supply cables. Will wrap them in electrical tape when connected.
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Unread 10-23-2009, 03:48 PM   #13
John Strenk
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Try Digikey for most any connector. You can get the tools also.
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Unread 10-23-2009, 04:02 PM   #14
93jeepyj
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Would you happen to have a diagram for the cj wiper switch? Im trying to use it to run my hardtop rear wiper since I kept the yj wiper controls on the stalk.
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Unread 10-24-2009, 02:50 AM   #15
John Strenk
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Wich wiper switch did you get? There are two of them, a 3 wire and a 4 wire switch. DO you have a schematic of the YJ rear wiper?
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