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Old 08-26-2014, 07:51 PM   #1
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Melted wires.

I recently bought a new set of off road lights for my TJ. I was hooking them up this evening. I hooked everything together and put the battery terminal back on. As soon as I did, the wires going to the toggles switch began burning and started melting. The harness provided had a hot wire going to the lights themselves with a ground wire I put on the negative battery post. Then there was another hot wire and negative going to the toggle switch. This is the wire that fried. Could anyone please help me. I have no clue about anything electrical related. Everything was essentially plug and play until this.

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Old 08-26-2014, 07:56 PM   #2
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Sounds like you had a hot shorted to ground somewhere along the line. Is there a relay in the circuit? What size wire? What wattage are the lights? Is there a fuse installed, and what size? Here's a typical wiring diagram for fogs.
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Old 08-26-2014, 08:11 PM   #3
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There is a relay and a fuse. I can't remember what size it was. The wire that melted was smaller gauge wire than everything else. It fed into a connector clip of some sort. The thicker heavier wire did not melt.
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Old 08-26-2014, 08:12 PM   #4
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What size and type of wire will I need to replace it with?
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Old 08-26-2014, 09:41 PM   #5
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Since I know nothing about the circuit you are playing with, I can't give you a wire size. Is this a manufactured harness that came with your lights that melted, or a Jeep harness? Need more info.
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