Smoking wire! -

LinkBack Thread Tools
post #1 of 5 Old 07-09-2011, 05:24 PM Thread Starter
Registered User
1980 CJ7 
Join Date: Mar 2010
Location: Tooele,
Posts: 26
Smoking wire!

Alright JF, Ive gota duzy here with my '80 Cj7
I installed a set of new Delta Hyperwhites that run the H4 bulbs and at 60/55
watts. After fixing a faulty ground, i left the headlights on to admire them. I
got back in the cab and the red w/ white wire was smoking and melting the
plastic on the harness for the headlight switch! It only smokes when I turn on
my brights though. After examining my diagram, i found that its my *foot dimmer switch feed*.so my questions are, is my dimmer switch faulty? or do i need bigger wire to make up for the new headlights? and how do I run relays for my new deltas?

thanks in advance!

Taylorettel is offline  
Sponsored Links
post #2 of 5 Old 07-09-2011, 05:37 PM
Registered User
1977 CJ7 
Join Date: Mar 2011
Posts: 3,869
You're pulling too many amps through the switch. Consider strongly a headlight relay under the hood and running heavier gauge wire for both 12V feed through the relay AND ground back to the battery or at least a ground buss. I DON'T KNOW THE FORMULA, but I'd run 10 gauge wire considering you're pulling about 700 watts.

I'd rather be lost on the trails than found at home!

Phoenix Rising- A Flame Off Restoration?
WindKnot is offline  
post #3 of 5 Old 07-09-2011, 05:43 PM Thread Starter
Registered User
1980 CJ7 
Join Date: Mar 2010
Location: Tooele,
Posts: 26

went out and checked again. This time , no smoke and no heat on the said wire. Now both high beams work and only left low beam works.
Taylorettel is offline  
post #4 of 5 Old 07-09-2011, 06:27 PM
Registered User
1985 CJ7 
Join Date: Sep 2008
Location: White Springs
Posts: 9,494
Have a look at this thread. It discusses the use of relays. I didn't read through the whole thing, but knowing Jeephammer, he probably explains in detail how to install. DON'T run your headlights the way you have them wired. You could end up burning down your Jeep!

Go Fish! <*////><

But the right word at the right time... "Hey, give me a little hug!" That's the difference between lightning and a harmless lightning bug!
Skerr is offline  
post #5 of 5 Old 07-10-2011, 07:13 AM
Registered User
1984 CJ7 
Join Date: Jan 2009
Location: Cape Cod
Posts: 811
The wiring upgrade is a must. Look at the above link. Once you get all the parts on hand it isn't as confusing to do.
I did this a while back and the difference is unbelievable.
CJunk is offline  

headlight switch , relay , smoke , wire

Quick Reply

Register Now

In order to be able to post messages on the forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page

Similar Threads
Thread Thread Starter Jeep Forums Replies Last Post
Headlight wire smoking! SAH_80_CJ7 Jeep CJ Forum 23 01-28-2011 04:19 AM
Converting Brake Pressure Switch from 2-Wire to 1-Wire Configuration checkman808 Jeep CJ Forum 4 01-12-2010 11:22 PM
smoking coil terminal (negative green wire) jimdubose Jeep CJ Forum 3 08-23-2009 02:31 PM
Wiper Motor Wire (3-wire vs 4-wire) TetanusCJ7 Jeep CJ Forum 0 07-18-2009 07:15 AM
Calling on Delco Alt Experts..Which is better: 1-Wire or 3-Wire?? hfjeff Jeep CJ Forum 2 04-05-2006 03:07 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome