It's only happen twice in the last few months, but on those occasions my headlights have not come on when I pull the **** out. After retrying 4 or 5 times they finally come on. Any troubleshooting hints would be appreciated. 95 XJ stock.

 

Its probably the switch. Unfortunately there is no relay taking the load off the switch.

Look into the putco wiring harness upgrade if you can, and maybe replace the switch.

 

http://www.eautoworks.com/Putco-H4--...s-PRD7540.aspx

Cruiser’s Headlight Upgrade Harness Instructions
　
It's easy to install a supplemental headlight harness.

From the factory, the voltage to the headlight bulbs travels from the battery, inside the cabin, to the headlamp switch, and then back out to the lamps via undersized wire. It's not uncommon to find only 10.5 volts at the lamps.

The supplemental harness is installed so that it provides battery voltage to the lamps and is just triggered by the factory wiring. The result is about 30% brighter headlamps and headlight switches that don't melt and burn out.
　
　

Absolutely plug and play. Remove grille and headlamp bulbs. I fed my harnesses from the passenger side starting between the battery and the back of the headlamp housing, over to the driver side. Plug the driver side bulb into the new harness. Attach the new harness's ground wire under one of the small bolts on the radiator support after scraping the paint off under it. Attach the harness to the existing harness behind the grille working toward the passenger side. . Plug the new harness plug into passenger headlamp. Plug original headlamp plug into receptacle on new harness. Attach the ground for the passenger side just like you did the driver side under a radiator support bolt. Attach relays with provided bracket on the passenger side inner fender. Connect power wires to battery.

Revised 12/10/2012