Jeep CJ- Lighting Upgrade Installation - JeepForum.com
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post #1 of 56 Old 02-19-2014, 06:15 PM Thread Starter
Matt1981CJ7
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Jeep CJ- Lighting Upgrade Installation

Evenin' Guys,

As we all know, the factory lighting on our CJs leaves a lot to be desired, especially the headlights. The main problem is how they are wired. The power runs from the battery thru the dash to the switch, then from the switch all the way out to the lights. The factory used small gauge wires with highly resistive contacts for these lengthy circuits, which causes an excessive voltage drop at the headlights.

The solution is to shorten the power path by using relays, which are simply an electrical switch. When the relays get power from the headlight switch, they complete a circuit from the battery directly to the headlights. Since this new circuit uses heavier wire, fewer contacts, and is a shorter distance from the battery to the headlights, the voltage drop is virtually eliminated.

Here are before and after wirings diagrams from Daniel Stern's excellent writeup on the upgrade.

Matt

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post #2 of 56 Old 02-19-2014, 06:21 PM Thread Starter
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So, I contacted Daniel Stern and put together the following order:

(2) 082440 - Cibie 7'' H4 headlamp lens-reflector unit - $158.00
(2) 48911 - Narva 100/55w H4 headlamp bulbs - $35.18
(1) HL28200 - Headlamp relay harness built-up for 2x H4 Jeep CJ - $161.49
(2) 2886X - Park or Marker bulb glass wedge upgrade 85-lumen - $9.18
(2) 796 - Reverse (back-up) upgrade bulb - $18.40
(4) 3496 - Bulb upgrade +45% brake/turn signal - $28.80

You can build your own harness for much cheaper, but it was worth it to me to have it professionally made. It consists of 2 Hella relays, 2 Hella fuses, and the necessary wire and connectors.

More after dinner......
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post #3 of 56 Old 02-19-2014, 06:45 PM
CSP
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Are those upgrade bulbs LEDs?


I'm upgrading all of my vehicles to true HID's with projectors. It should be a huge improvement in all of them.
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post #4 of 56 Old 02-19-2014, 06:51 PM Thread Starter
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First, I mounted the relays as close to the battery as I could.

Then, I mounted the fuses on the front clip brace, since I couldn't find a better place for them. I was limited by the length of the pre-made harness, and the configuration of my dual batteries. If you make your own harness, you can control where everything gets installed.
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post #5 of 56 Old 02-19-2014, 06:58 PM Thread Starter
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After removing the headlights, I routed the new harness thru the grill on the passenger side, and connected it to the old harness.
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post #6 of 56 Old 02-19-2014, 07:03 PM Thread Starter
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Then I installed the new bulbs in the new reflectors, put on the supplied waterproof boots, and reinstalled the headlights.
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post #7 of 56 Old 02-19-2014, 07:07 PM Thread Starter
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Lastly, I installed the upgraded bulbs for the side markers, rear brakes/turn signals, and reverse lights.

Now, I have to shoot the 'after' pics. Back in a few....
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post #8 of 56 Old 02-19-2014, 07:11 PM
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Nice looking setup. I like those fuse holders better than what I used in my harness (may have get a couple and integrate them).
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post #9 of 56 Old 02-19-2014, 07:17 PM
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I dig the water proof boots too... Were those included with the lights or a seperate PN?
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post #10 of 56 Old 02-19-2014, 07:53 PM Thread Starter
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The boots were included with the reflectors.

Here's the before and after pics on high beams. I'm impressed!

Matt
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post #11 of 56 Old 02-19-2014, 07:58 PM
UBERK
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Nice....
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post #12 of 56 Old 02-19-2014, 08:13 PM
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Now go wipe the finger prints off the globes and they will last longer. Alcohol wipes work well.
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post #13 of 56 Old 02-19-2014, 08:17 PM
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Gonna be able to see you coming clear from my house.
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post #14 of 56 Old 02-19-2014, 08:20 PM
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Lets see the new rears......
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post #15 of 56 Old 02-19-2014, 08:56 PM Thread Starter
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Quote:
Originally Posted by UBERK View Post
Lets see the new rears......
Unfortunately I didn't shoot any before pics of the rears...doh!. The difference is significant.

Matt


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