Putco headlight wire harness install
CF Veteran
Joined: Jul 2012
Posts: 4,104
Likes: 2
From: San Antonio, TX
Year: 1996
Model: Cherokee
Engine: 4.0L
I ran out of money for mods this week so i coulndt do fuses :/ eventualy 
Im running hella E-codes with som sylvainia silverstars and love it! Stock lighting SUCKS

Im running hella E-codes with som sylvainia silverstars and love it! Stock lighting SUCKS
After a month. I bought and installed my putco harness with inline 30a fuses. Autopal s glass and hella 100w bulbs. This thing really is like day and night difference. I turned my lenses alittle lower than stock to not blind others. I will advise that before you install the harness to recrimp each wire into each plug. I lost lows while driving and found the low power wire after relay came out. After that fix everything has been fine. Knock on wood lol. The upgrade is well worth the money. Now time to put in some kc lights.
Senior Member
Joined: Jul 2009
Posts: 739
Likes: 0
From: San Diego, CA
Year: 1996
Model: Cherokee
Engine: 4.0 HO
I just got done installing the wire harness and the Hella 60w/55w. Pretty easy install thanks to everyone's input. I did run into a problem in that the Jeep didn't start up after install! Turns out the main ground and the positive terminal wires were loose. At some point, I'll go back in and beef up the headlight grounds. Probably when I install the Hella 500 aux lights I have. But for now, it's amazing to see the lane reflectors lit up like they were powered and I can see SO much further! The only thing I want to add are fuses, but no one has said with absolute knowledge what amp fuses to use. So far I've seen 15 amps and 30 amps...
Senior Member
Joined: Dec 2011
Posts: 922
Likes: 1
From: Centralia, Wa
Year: 1997
Model: Cherokee
Engine: 4.0
Depends on wattage of headlight. 55x2 is 110 divided by 12 is 9.1. So your going to want to fuse for something around that. Depending on wire size and connection ratings you should be good with a 15 or 20.
Senior Member
Joined: Jul 2009
Posts: 739
Likes: 0
From: San Diego, CA
Year: 1996
Model: Cherokee
Engine: 4.0 HO
Ah, okay. So if I got the 60/55w, I suppose I could calculate from the 60 (x2=120/12) which is 10 amps. So you figure a 15 or 20 for that rating, too, right? And put the fuse between the disconnect and the battery terminal, I'm guessing. So if something fries, it'll only happen before the connector.
Do yourself a favor, and get a couple of spare relays to keep in the glove box.
Those relays are junk, and don't last very long(DAMHIK).
They are not a common replacement, so not everyone carries them.
Just fore-warning you.........
Those relays are junk, and don't last very long(DAMHIK).
They are not a common replacement, so not everyone carries them.
Just fore-warning you.........
Junior Member
Joined: Jul 2011
Posts: 35
Likes: 0
From: New York
Year: 1999
Model: Cherokee
Engine: 4.0
And remember,anyone with O.E.M. fog lights,It's a good chance your high beams won't cut off as designed. Easy fix (especially if you don't use fog lights) is pull fog light relay.there are other fixes. none are difficult.
Member
Joined: Feb 2012
Posts: 126
Likes: 0
From: Dickinson, ND
Year: 2000
Model: Cherokee
Engine: 4.0
Didn't want to start a new thread. I installed sylvania silverstar sealed beam headlights a couple months ago. My headlights now flicker at random. Will this kit (just ordered one) fix the issue or will I still need a new headlight switch? Thanks!
::CF Moderator::
Joined: Aug 2011
Posts: 43,971
Likes: 1,578
From: Prescott, Az
Year: 1990
Model: Cherokee (XJ)
Engine: 4.0
You may be fine with just the harness. I actually think you will be because the amp load will be removed from the switch with the harness installed. Try it and report back to this thread please.
::CF Moderator::
Joined: Aug 2011
Posts: 43,971
Likes: 1,578
From: Prescott, Az
Year: 1990
Model: Cherokee (XJ)
Engine: 4.0
CF Veteran
Joined: Dec 2012
Posts: 4,169
Likes: 6
From: York, PA
Year: 1998
Model: Cherokee
Engine: 4.0
Excellent thread and write-up! I'm fed up with the stock lighting on my '98 Sport. I think the camera flash on my cell phone is brighter. So, from the factory, all the power is routed THROUGH the headlight switch? That's pretty derpy. Mine also has the factory fog lights--real frustrating that they switch off when I switch on high beams (term used loosely). I plan on removing these and replacing them with offroad lights when I get my bumper and rewiring them so they don't switch off with high beams.
Will this harness work with the Rampage upgrade? I kinda like the looks of that but maybe it's cheaper to get the harness and silverstars?
Will this harness work with the Rampage upgrade? I kinda like the looks of that but maybe it's cheaper to get the harness and silverstars?
Senior Member
Joined: Dec 2011
Posts: 922
Likes: 1
From: Centralia, Wa
Year: 1997
Model: Cherokee
Engine: 4.0


