My headlights went out!
Senior Member





Joined: Oct 2019
Posts: 789
Likes: 234
From: Current XJ is
Year: 95
Model: Cherokee (XJ)
Engine: 4.0
Shining up the connection still doesn't fix the undersized wiring. Pushing 10-amps through around 10-feet of 16-gauge wire will drop 0.8 volts. That's ignoring the losses upstream of the headlight switch, and the ground path. So, that 6% loss puts you around 80% of the power to the headlight that you could be getting by using a dedicated wiring harness of a reasonable size.
The harness made a noticeable difference on my 89, and picked up about 1-volt at the headlights with stock bulbs. Then I installed a pair of e-code housings an 55/100 bulbs. I don't get flashed with the sharp cutoff on the low beams, and the high beams are are super bright long distance deer spotters.
CF Veteran




Joined: May 2012
Posts: 7,965
Likes: 964
From: Lost in the wilds of Virginia
Year: 1998 Classic (I'll get it running soon....) and 02 Grand
Model: Cherokee (XJ)
Engine: 4.0
Senior Member





Joined: Oct 2019
Posts: 789
Likes: 234
From: Current XJ is
Year: 95
Model: Cherokee (XJ)
Engine: 4.0
Thread Starter
Old fart with a wrench
Joined: Nov 2010
Posts: 14,398
Likes: 741
From: Manlius, east of Syracuse, NY
Year: 2000 XJ Sport & WJ Laredo
Model: Grand Cherokee (WJ)
Engine: 4.0L
My first experience with relays was in my 1937 Dodge with it's 6v system. I used a universal truck headlight relay and it made a HUGE difference! Everybody thought I'd converted to 12v!
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