Headlight Harness Upgrade?
Senior Member
Joined: Oct 2019
Posts: 789
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From: Current XJ is
Year: 95
Model: Cherokee (XJ)
Engine: 4.0
dc power does not just travel on the surface, if that were true, dc wires would be made extremely thin, but very wide for best current capacity, but that is not the case.
corrosion of wires does reduce the wire cross section of low resistance metal, and corrosion can go deep into the cross section, making a very good resistor out of portions of the wire.
on the 1990 xj the headlamp ground is on the inner driverside fender well, near the aircleaner. make sure that ground point is good. adding relays can help a lot.
corrosion of wires does reduce the wire cross section of low resistance metal, and corrosion can go deep into the cross section, making a very good resistor out of portions of the wire.
on the 1990 xj the headlamp ground is on the inner driverside fender well, near the aircleaner. make sure that ground point is good. adding relays can help a lot.
Wire in DC applications is stranded even in stationary installations where flex is not needed at all like chassis wiring for example.
AC wiring in stationary applications, like buildings for example, is solid.
WIre and cable in stranded round form are more flexible and fatigue resistant than they could ever be in flat ribbon form.
Last edited by ijeeep; Feb 26, 2021 at 12:34 AM.
::CF Moderator::
Joined: Aug 2011
Posts: 43,971
Likes: 1,579
From: Prescott, Az
Year: 1990
Model: Cherokee (XJ)
Engine: 4.0
Relays/harness is the only way to go.
The system is so underdesigned that even with good ground contact, the switch gets hot and melts inside.
The system is so underdesigned that even with good ground contact, the switch gets hot and melts inside.
Thread Starter
Senior Member
Joined: Jul 2015
Posts: 694
Likes: 50
Year: 1989
Model: Cherokee
Engine: 4.0
Just to finish this thread up. I got the the new harness in, with two new head lights. My lights are so bright now it is like a luxury vehicle to me. Way brighter than stock set up.
I also got my blinkers back working for the moment. That was a ground issue. Will nees to put a new bulb socket in the front right next week to male sure it stays solved.
Surprising how just having blinkers and bright head lights makes such a difference.
I also got my blinkers back working for the moment. That was a ground issue. Will nees to put a new bulb socket in the front right next week to male sure it stays solved.
Surprising how just having blinkers and bright head lights makes such a difference.
Junior Member
Joined: Jul 2020
Posts: 50
Likes: 10
From: Los Angeles, CA
Year: 2001
Model: Cherokee (XJ)
Engine: 4.0
It might be easier to pay a little more money & atleast, perhaps get direct support if you have trouble with your install. Check these guys out.
https://www.ksuspensionfab.com/store...Harness.html#/
https://www.ksuspensionfab.com/store...Harness.html#/
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