Ok, I know this has been beat to death, but I haven't looked into it in many years, and the searches I've done have some outdated links. I have the front off of the Jeep in order to do a timing chain, so I figure might as well upgrade now.

I see a few from Octane Lighting, but not sure if there is a specific one for XJ's.

Thanks for any info / links !

 

Hah I just finished doing the wiring upgrade and made a post here fifteen minutes after you made yours. If you have factory fogs, don't forget to do the splice mod so that the high beams don't stay locked on. Personally, I would build your own wiring harness. It will cost you less than half of what the "quality" $100 kits cost. I could probably make one for about thirty bucks. Just get two quality waterproof relays and a bunch of 12 AWG wire, wire loom, and the special headlight connector sockets (the ceramic ones that can take the heat). You'll need to get a male headlight plug adapter too as that is what triggers the relays. You can use 16 AWG for those wires. My next mod will be to upgrade the wiring for the fog lights. The factory used the smallest diameter wire those cheapskates. There are wiring diagrams for the headlight harness all over the internets. Looking back after my project today, I wish I would have just made my own harness using better wire. The chinese kits are pure crap but still made an improvement over stock.

 

I've got both the Putco harness... And this harness from True Mods... .. The first one is the old tried and true from the old threads everyone loved at one time but has all but doubled in price since I bought it years ago... I bought the second because I've already installed some of their components and they're good quality with the bosch style relays and appears to be better components in general... I'm sure either one will get the job done...

 

The True Mods appears to be the same chinese stuff thats floating around the internet vendors for $17-25. I haven't read many complaints about them. I'd just consider pulling out the positive supply wire that goes into the relay from the battery and at least bumping that wire up to 12 AWG. The wires look thick but they really have only a few strands of copper in them lol.

 

So the True Mods link shows a harness for Toyota etc. Are those the same as the XJ's ?

 

Yes, scroll down to the top reviews...5th down..... You'll see XJ owners who have used it...Right above the wiring issue pics...lol... There's a whole lot of good reviews but the few bad ones sure leave you scratching your head... In any case I haven't used either one yet.. And will modify which ever one I use regardless...

 

I installed the K-Suspension one in my XJ. Seems to be okay. I guess I'll know if it lasts. It was $25+ shipping. I could have made one but I'm trying to not do everything myself from scratch, lol. I have a tendency to do that.

Good on you guys that make your own harnesses. They are probably better.

 

I used "Headlight services" out of denver several years ago..no issues simple install 2001 no fog or drl

 

I decided to just go with the True Mods kit, since I'm not sure I could buy and have shipped all of the components to make my own.
I'll upgrade the pos+ wire to 12awg, seal the relays. and call it good. It will be nice to have decent lights after 20+ years.

Thanks much guys !

 

Anyone have a favored electrical schematic and details for the setup that utilizes a relay to switch headlamp power? I would rather make my own wiring upgrade. I want to continue to use the Hella Vision Plus conventional lamps I have installed so I don't need an LED conversion setup. My approach is to keep my '91 closeer to stock in parts and appearance.

 

Here's an example. A variation is to use 2 fuses (one to each relay). Size the fuse(s) to match the draw for the headlights. You can also tie the grounds together and then have a single point to connect to the chassis.

https://www.hipoparts.com/headlight-...rness-project/

 

If you're going to d-i-y, this is probably (still) the definitive guide: http://gojeep.willyshotrod.com/HowtoHeadlightLoom.htm
It's the way I did my 1st XJ but I was surprised by the total cost (& those male H4 plugs weren't even available then - at least in the UK) not sure it's economically viable.

I used one for an S10 (similar size & battery position) the 2nd time, don't remember the brand, not overly impressed with some of the crimping & the relays are unlike any others I've seen, but do have nice sockets, I also modified to replace the ground for the LH light back to the battery, that said works well enough.

I bought an el cheapo one of FleaBay for my Citroen van, altogether odd because it had an extra, unexplained component so the seller sent me another but, meanwhile I'd installed the original, after devising a work round, so now have a spare, which might go on my KJ (it's a Jeep, so has the hallmark poor lowbeams!).

That TrueMods kit looks OK (Chinese or not) but noticed the ref. to -ive switching (which I believe some Tacomas used) which is not right for an XJ; Headlight Services, e.g. recognise this & offer both.

2 fuses is an approach, means if one fails, you still have some lights to get home (or at least off the trail) by that can be taken a stage further by using 4 relays but really only comes into its own with high wattage bulbs - & they're a bit 20th century now.

 

Thank you Saudade and UKXJ. Both posts are very helpful.