CJ5 Headlight Upgrade Help

Hey cj5chic, I don't have any experience with LED headlamps, but did purchase this harness to use with my existing halogen H4 stock headlamps.

https://www.amazon.com/dp/B00H5JFHR...olid=1WZOU8N8TPW91&psc=0&ref_=lv_ov_lig_dp_it

Wow, what a difference when 12 full volts were routed directly to the headlamps as opposed to the original configuration of running power from the battery through the harness to the light switch and THEN finally to the headlamps. Although this product looks generic, the harness came to me as a Hella brand (nice quality), and was simple to install and did not require any modification of the original harness (big plus for me). Virtually plug and play once you identify your routing and where to hang the two relays. In my mind, the other bonus is not having to contend with possible fitment issues on a aftermarket LED bulb to the original headlight buckets. Plus you cut your proposed cost in half! Just my thoughts...

Best,
Hoov

Chic,

I'd be leery of those high wattage bulbs for a couple of reasons. First, many states have restrictions on the amount of wattage headlights can have. I think it's around 100W for high beams and 50W for low beams. Second, high wattage bulbs will put an additional strain on the already poor headlight circuit in your CJ, which could cause wires to overheat.

What many of us have done to improve the headlights is to add a relay harness, which drastically improves the voltage to the headlights. Along with upgraded bulbs, the difference is profound. It's a very easy plug and play deal. Here's my thread on the upgrade. You can do it cheaper than I did, if you shop around for the parts.

https://www.jeepforum.com/forum/f8/jeep-cj-lighting-upgrade-installation-2130225/

Before and after pics below.

Matt

There does not currently exist any 7" LED headlight that will bolt into a CJ without modification, though they all like to market them as if they will. They all require something be done, some more than others. Check out my build thread if you want a taste of what it takes. It's really not that bad. If you use projector type LED's you can aim them very well as to not blind oncoming cars. They have a very focused pattern.

But to keep life simple you probably should stick with the headlights you already have and purchase a relay kit to power them. Many vendors on amazon sell the kit for around $25. Hoov's link above are $35, but appear to be very good quality. I bought it.

Your factory wiring is the main problem. All the amazon kits are nearly plug and play. They use your factory wiring and headlight switch only to trigger the relays. 40 year old crusty wiring is still capable of that job, cause it takes just miliamps to trigger the relays. The new relays and their associated wiring carry the current load.

cj5chic said:

Thanks guys for the feedback. I so appreciate you help and wisdom!😘
I think I'm starting to wrap my head around this... almost.
What does H4 mean?
These are the headlights I have now.
SYLVANIA H6024 XtraVision Halogen Sealed Beam Headlight (7" Round) PAR56, (Contains 1 Bulb) https://www.amazon.com/dp/B000C18Q44/ref=cm_sw_r_cp_apa_i_QEidCbYK0PWDS
Will a relay harness work with these existing headlights?

Click to expand...

Nothing wrong with your sealed beam headlights, generally considered to be a good quality brand and no corrosion issues.

An H4 headlight housing is not sealed, it is open at the back and you can put in an H4 size halogen bulb. Generally considered to be an upgrade as it gives a range of available bulbs etc. Hella are a good brand, but you do not need to change out your Sylvania.

Your problem is that the voltage at your bulb is not battery level i.e. 13,5V when running. Your old wiring, dodgy switches and porr ground path may only be delivering 10.5V. This would reduce output by more than 40%.

Rather than spend money on fancy bulbs, fix the harness. A relay harness will allow battery voltage to be supplied at the bulb and a much better return path to the battery. Only fit one that has a return ground to the battery, do not ground it locally to the grille or fender. You will find your headlights are super bright.

All my Cjs with relays drive fine at night, only one has the original harness and it is guesswork at night. Puthijeep has relays, thick wires, Hella H4 housings and Philips bulbs, brilliant.

TIPPEDITOVER said:

I just bought the $35 plug and play kit you linked from amazon. Seems legit.

Click to expand...

I was was pleasantly surprised, Tipped. From the amazon images, I was expecting a much more cheaply made unit. Once in hand, though, it was well put together, used Hella relays, shrink wrapped, and enclosed in a loom with zipties.

For my setup, it was easiest to keep the harness on the passenger side and use the passenger side headlight harness plugs to operate the relays. I used the positive side of the solenoid for power, and grounded to my buss bar behind the battery. The hardest part was taping up the unused original harness plugs after removing the headlight and buckets.

Edit: My apologies for the first image, can't seem to delete it. :dunno:

Edit2: Ahh, fixed it.

Hoov

Hoover7 said:

....

Edit: My apologies for the first image, can't seem to delete it. :dunno:

Hoov

Click to expand...

OOPS, Sorry about that. I tried to help you with deleting the first picture but I did the wrong one.
Please re-post that picture again.

Here is how you delete an uploaded picture:

Well it looks like animated gifs do not work here.
here are the steps
1. Go to Edit
2. Go to Advance Edit
3. Go to Upload Pictures.
4. SCROLL DOWN.
5. Select the picture you want to delete.
6. Done!