1995 XJ The headlights turn off after about 10 mins running, Headlight switch was replaced about 2 years ago, helped until recently. Using H1 headlights 55 watt, so not a big bulb.
Working the switch when they go out sometimes turns them back on, or they come on by themselves eventually. Is there a relay in the headlight circuit that could be weak? Thanks!

 

No relay and that's the problem with the XJ's headlight circuit. After checking the connector at the back of the switch for any damage I'd upgrade to an aftermarket headlight harness (has two relays) and replace the switch. Better lighting and a safer system.

 

CRUISER'S MOSTLY RENIX TIPS

HEADLIGHT HARNESS UPGRADE

NOVEMBER 17, 2015 SALAD 42 COMMENTS EDIT



It’s easy to install a supplemental headlight harness.

From the factory, the voltage to the headlight bulbs travels from the battery, through connectors, inside the cabin, to the headlamp switch, and then back out to the lamps via undersized wire and more connectors. 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 35% brighter headlamps and headlight switches that don’t melt and burn out.

Here’s a link to a harness on ebay: http://www.ebay.com/itm/CERAMIC-H4-H...-/330997592807

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 1-31-2016

 

I clicked on the link you showed and it says does not fit my 94 sport??? Or is it my computor or idiot operator?? thank you for any reply or more advice..

 

It'll fit. It's more than likely that it could fit so many different vehicles, they just aren't listed. As it's not a genuine part or aftermarket replacement of an original part, it's up to the seller to list what it's for.

 

It fits.......

 

Thank you all for replys. I ordered one and will try it and a new HL switch..

 

There is a circuit breaker in the junction block that overheats and opens, then cools and closes. That's why the headlights come back on by themselves. Over the years this circuit breaker gets weak and pops easier than it should. You probably don't need a new switch once you get the high load off the circuit. The relays in the upgraded harness only draw about 1 amp each, where the headlights draw about 35 amps.

 

Just wanted to let you all know that the Harness worked out GREAT..We have had this jeep since new in 94..The light have never been this bright.Harness was plug and play as said to be..Only problem was dropping trim screws on the floor and getting D/S light plug around corner into HL bucket..All worked fine and Thanks again to all..

 

Amazing, isn't it?