DOT approved aftermarket LED headlights???
CF ADMIN

Joined: Sep 2010
Posts: 34,088
Likes: 257
From: Lantana, Fl
Year: 1996
Model: Cherokee (XJ)
Engine: 4.Slow
^^^This in short, each state has it's own laws on whats legal and what's not. What may be legal for me in FL, may not ne legal for use in say CA.
Look into your specific states laws/requirements on equipment before you drop a good amount of money on something you may not be able to use where you live.
Look into your specific states laws/requirements on equipment before you drop a good amount of money on something you may not be able to use where you live.
Banned
Joined: Feb 2014
Posts: 2,379
Likes: 18
From: Florida
Year: 2000
Model: Cherokee(XJ)
Engine: Golen 4.6L
Federally speaking, the short answer is that headlights must be DOT compliant. For the long version, see full text of the law in link below.
The states enforce that law and set their own. There is variation from state to state, but the spirit of the law in most if not all states is always the same.
I won't be posting the full text here as legalese is incredibly verbose. Anyone interested and capable of understanding it should be capable of clicking a link.
Federal - http://www.ecfr.gov/cgi-bin/text-idx...e49.6.571_1108
Wisconsin - http://docs.legis.wisconsin.gov/stat...atutes/347.pdf
The states enforce that law and set their own. There is variation from state to state, but the spirit of the law in most if not all states is always the same.
I won't be posting the full text here as legalese is incredibly verbose. Anyone interested and capable of understanding it should be capable of clicking a link.
Federal - http://www.ecfr.gov/cgi-bin/text-idx...e49.6.571_1108
Wisconsin - http://docs.legis.wisconsin.gov/stat...atutes/347.pdf
Do those links say that only OEM is acceptable?
Federally speaking, the short answer is that headlights must be DOT compliant. For the long version, see full text of the law in link below.
The states enforce that law and set their own. There is variation from state to state, but the spirit of the law in most if not all states is always the same.
I won't be posting the full text here as legalese is incredibly verbose. Anyone interested and capable of understanding it should be capable of clicking a link.
Federal - http://www.ecfr.gov/cgi-bin/text-idx...e49.6.571_1108
Wisconsin - http://docs.legis.wisconsin.gov/stat...atutes/347.pdf
The states enforce that law and set their own. There is variation from state to state, but the spirit of the law in most if not all states is always the same.
I won't be posting the full text here as legalese is incredibly verbose. Anyone interested and capable of understanding it should be capable of clicking a link.
Federal - http://www.ecfr.gov/cgi-bin/text-idx...e49.6.571_1108
Wisconsin - http://docs.legis.wisconsin.gov/stat...atutes/347.pdf
S6.5.1 DOT marking. The lens of each original equipment and replacement headlamp, and of each original equipment and replacement beam contributor, and each replacement headlamp lens for an integral beam or replaceable bulb headlamp, must be marked with the symbol “DOT” either horizontally or vertically to indicate certification under 49 U.S.C. 30115.
And Sec. 547.3125. disproves that claim in my state of Texas.
http://www.statutes.legis.state.tx.u...htm/TN.547.htm
I suspect that most, if not all, other states word their equipment requirement statutes similarly to TX 547.3125.
Senior Member
Joined: Mar 2012
Posts: 974
Likes: 14
From: Racine, WI
Year: 1997
Model: Cherokee
Engine: 4.0
Thread Starter
Junior Member
Joined: Aug 2015
Posts: 64
Likes: 0
From: Mid-Michigan
Year: 1989
Model: Cherokee
Engine: 4.0l
First thing you ought to do is buy 1 of these or make your own.
http://www.ebay.com/itm/Putco-230004...5UIMQl&vxp=mtr
http://www.ebay.com/itm/Putco-230004...5UIMQl&vxp=mtr
CF ADMIN

Joined: Sep 2010
Posts: 34,088
Likes: 257
From: Lantana, Fl
Year: 1996
Model: Cherokee (XJ)
Engine: 4.Slow
Banned
Joined: Feb 2014
Posts: 2,379
Likes: 18
From: Florida
Year: 2000
Model: Cherokee(XJ)
Engine: Golen 4.6L
mschi772 posted a link to a more comprehensive explanation on the first page, but to sum up:
The headlight circuit on an XJ runs the full power used by the headlights through the headlight switch. Over time, the wires and connections in this circuit become corroded and build up resistance. When electrical current hits resistance, it's transformed into heat, which damages insulation, connectors and switches. Resistance also allows less current to flow to the headlights, causing them to become dim. In extreme cases, the heat damages the headlight switch and can actually cause it to catch fire.
The relay harness bypasses the original circuit to power the lights directly from the battery, giving them full power so that they return to their original brightness. The difference is immediately noticeable. Additionally, the full load no longer passes through the headlight switch. Only enough current has to pass through to trip the relay when you operate the switch. The relay is then what actually turns your lights on and off. Thus in addition to giving you brighter headlights, it also protects your headlight switch from damage and failure.
What was linked above is the Putco harness, which is fine. However, there's a generic Ebay harness that uses ceramic connectors and better relays that actually costs less money but gets good reviews:
http://www.ebay.com/itm/CERAMIC-H4-H...-/330997592807
It takes anywhere from half an hour to 2 hours to install, depending on your level of adeptness with the tools. If you can use a drill and a screwdriver, you can do this. It's one of the easier mods, and it gives immediate results.
The headlight circuit on an XJ runs the full power used by the headlights through the headlight switch. Over time, the wires and connections in this circuit become corroded and build up resistance. When electrical current hits resistance, it's transformed into heat, which damages insulation, connectors and switches. Resistance also allows less current to flow to the headlights, causing them to become dim. In extreme cases, the heat damages the headlight switch and can actually cause it to catch fire.
The relay harness bypasses the original circuit to power the lights directly from the battery, giving them full power so that they return to their original brightness. The difference is immediately noticeable. Additionally, the full load no longer passes through the headlight switch. Only enough current has to pass through to trip the relay when you operate the switch. The relay is then what actually turns your lights on and off. Thus in addition to giving you brighter headlights, it also protects your headlight switch from damage and failure.
What was linked above is the Putco harness, which is fine. However, there's a generic Ebay harness that uses ceramic connectors and better relays that actually costs less money but gets good reviews:
http://www.ebay.com/itm/CERAMIC-H4-H...-/330997592807
It takes anywhere from half an hour to 2 hours to install, depending on your level of adeptness with the tools. If you can use a drill and a screwdriver, you can do this. It's one of the easier mods, and it gives immediate results.
Last edited by extrashaky; Nov 5, 2016 at 11:39 AM.
Just adding the headlight harness will give your stock lights about 20 to 30 percent more light.And it will help your headlight switch last a lot longer since the load is taken off it.Then if you add a better set of h4 housings and lights you'll have a lot better headlights.
Banned
Joined: Feb 2014
Posts: 2,379
Likes: 18
From: Florida
Year: 2000
Model: Cherokee(XJ)
Engine: Golen 4.6L
I have a set of Hella e-code H4 housings in my XJ with 55/100W halogen bulbs. My Subaru has factory HIDs, so I have a direct comparison. The projector lamps in the Subaru have a better cutoff in low beam and spread the light better, but are only slightly brighter than the H4s. However, those 100W high beams in the XJ blow away the HID high beams in brightness, and they flood light evenly where the HIDs have an odd spot pattern that always seems to put the brightest light in the wrong place. On dark country roads, I prefer the H4s over the much newer technology.
The point of sharing that is this: People always want to jump to the more complicated, newer conversions or to the flashiest new gimmick, when the tried and true H4 conversion with a relay harness is simpler and can be more effective. I haven't used a set of Truck Lites yet, but I have my doubts that they'll give me a big enough boost in performance over the H4s to justify the extra cost. Between H4 and those stupid Chinese Ebay LED bank headlights, there's just no contest at all.
The point of sharing that is this: People always want to jump to the more complicated, newer conversions or to the flashiest new gimmick, when the tried and true H4 conversion with a relay harness is simpler and can be more effective. I haven't used a set of Truck Lites yet, but I have my doubts that they'll give me a big enough boost in performance over the H4s to justify the extra cost. Between H4 and those stupid Chinese Ebay LED bank headlights, there's just no contest at all.
You also don't need a harness upgrade with LED's because the power draw is so much smaller. I remember reading one guy installing the harness after a set of Truck-Lites and seeing absolutely no difference in output.
Senior Member
Joined: Mar 2012
Posts: 974
Likes: 14
From: Racine, WI
Year: 1997
Model: Cherokee
Engine: 4.0
I still recommend it. It's not all about output. It's also about protecting your wiring/headlight switch.
im running h4 conversion headlight housings with putco led h4 bulbs part number is 270004. what a world of difference. heck of a lot better than halogens. and a lot more reliable than cheap ebay HIDs, take a look into it you'd surprised.


