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Headlight problems 96xj classic.

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Old 10-19-2018, 04:53 PM
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Default Headlight problems 96xj classic.

Hello friends. Sorry for the spamming but I'm trying to knock these problems out one at a time. I'm having the issue of my headlights turn themselves off and on which I hear is a common problem.

I've done some googling and they say there's a diy fix but I couldn't find any specifics searching the forums. I have noticed some extra wiring leading up and out of the firewall with some fuses spliced in to them which may be the fix in question but those were long rotted out.

I have attached some pics of what I have going on down here if anything looks familiar. The black and pink wires were spliced in to the red and blue wires which I assume are ignition. Behind the pink and black wires was a junction with two fuses in it. The wires coming out the other side of the firewall were blue and red iirc (I didn't take a picture before I yanked them, sorry) but in the second pic the red wire leading to the headlights was secured under a bolt for the airbox and blown up lol.

If anyone can take a look and tell me what they think I have going on here that'd be great and I'd much appreciate a link to a write up/thread on the fix for the headlight problem.

If you need any pics or more info please let me know. Thanks guys!


Old 10-19-2018, 05:55 PM
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Not sure what your wires are for, but the headlights going off is very common. The problem is the factory headlight switch can't handle the amps they send through it so when it gets hot, the lights shut off. The accepted fix is to install some relays so all the amperage doesn't go through the switch. You can buy a premade harness with relays online, or if you are good at electrical work make one yourself. Some people have used the Putco harness, but there are others out there.
Old 10-19-2018, 06:18 PM
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Originally Posted by Garrett S.
Not sure what your wires are for, but the headlights going off is very common. The problem is the factory headlight switch can't handle the amps they send through it so when it gets hot, the lights shut off. The accepted fix is to install some relays so all the amperage doesn't go through the switch. You can buy a premade harness with relays online, or if you are good at electrical work make one yourself. Some people have used the Putco harness, but there are others out there.
I wonder how much cheaper it would be to build my own. You'd think someone would have come out with a heftier switch by now.
Old 10-19-2018, 06:23 PM
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I know there's a cheaper one out there, I don't remember where though. Replacing the switch with a new one helps for a while, but It will do the same thing again eventually.
Old 10-19-2018, 10:14 PM
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Default Headlight Wire and Relay Project

Hand made my harness and relay circuits. Don't regret it one bit. Never had the lights go out since. Do same. Design you own. Relays near the battery on the firewall.

Old post and pic here:

https://www.cherokeeforum.com/f67/he...2/#post3165068
Old 10-20-2018, 09:31 AM
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About $20 delivered. I've installed about 10 of them.

http://www.ebay.com/itm/CERAMIC-H4-H...-/330997592807
Old 10-20-2018, 10:44 AM
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Originally Posted by cruiser54
About $20 delivered. I've installed about 10 of them.

http://www.ebay.com/itm/CERAMIC-H4-H...-/330997592807
I loved happyTrails idea but $20 sounds about right lol. Thanks bud.
Old 10-20-2018, 02:35 PM
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Originally Posted by GalvanizedHero
I loved happyTrails idea but $20 sounds about right lol. Thanks bud.

You bet. Enjoy your brighter head lights!!!!
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