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Old 10-28-2012, 03:30 AM   #1
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Headlight upgrade problem help please

Ok,
My job has me driving 60+ miles each day and its on backwood country roads with no lights. I get this idea to upgrade my lights,, nice weekend project right?
I installed 2 KC H4 headlights and 2 Hella foglights, Headlights were plug and play and fogs wired into the existing fog light wiring. All was great until last night.

On the way home with the high beams on the headlight on the drivers side browned out and the fogs shut off leaving me with one light, I immediately went to low beams and shut off the fogs. Drivers side stayed brown and the High beam indicator in the instrument cluster remained illuminated. I tried turning the fogs back on and they worked, and so I limped home. Eventually the drivers side came back on and then went brown again.....

Any ideas? Switch,, Relays???
TY in advanced for any help

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Old 10-28-2012, 07:00 AM   #2
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What are the wattage of the lamps.

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Old 10-28-2012, 08:00 AM   #3
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Quote:
Originally Posted by Atthehop View Post
What are the wattage of the lamps.
H4 55/60 watt headlamps


KC HiLites Performance 7” Round Headlamp Kit for 45-06 Jeep® CJ, Wrangler TJ & Unlimited - Quadratec
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Old 10-28-2012, 08:02 AM   #4
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Originally Posted by Atthehop View Post
What are the wattage of the lamps.
First guess would be the wattage is too much for the "stock" wiring on the Fogs....next best Guess would be that "replacement" headlights are too much for the "stock" wiring on the headlights...next guess would be a bad ground.

I did the same "Mod" with my lights and have had NO PROBLEMS....but it is going to depend on how you wired things up and the light wattage.

There are aftermarket lights that just pull WAY TO MUCH amperage for the factory wiring harness, and that COULD be the issue.

As the Fogs and headlights are "wired together" so that you shouldn't be able to use fogs and high beams at the same time that MIGHT be the issue, and again goes back to the factory wiring harness/ light wattage.

I installed a "toggle" switch for my fogs but jumped into the harness out under the hood on the driver's side of the factory loom. This enabled me to use the "factory harness" and my own seperate relays and not worry too much about overloaded circuits.

Good LUCK!!

IMO Hella's probably too much. I used KC replacement fogs.
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Old 10-28-2012, 09:03 AM   #5
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I run 2 135watt H4's headlights and 2 100 watt driving lights and wired all of them using relays to prevent overheating the factory wiring which could never handle the load. Start tracing your wiring looking for melted points and start splicing.
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Old 10-28-2012, 03:15 PM   #6
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So does anyone think that the same KC 55/60 replacement headlamps Akita listed would have had the same problem if the fog lights were these 55 watt replacement/plug and play KC hilights 1131 fog lights
KC HiLiTES 1131 - KC HiLiTES Replacement Fog Light for 97-04 Jeep Wrangler TJ & Unlimited - Quadratec
I have the same year jeep unlimited and was looking at the same upgrade. Don't want to fry my wires and leave me in the dark on the way to work!
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Old 10-28-2012, 03:34 PM   #7
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Originally Posted by jp2611 View Post

As the Fogs and headlights are "wired together" so that you shouldn't be able to use fogs and high beams at the same time that MIGHT be the issue, and again goes back to the factory wiring harness/ light wattage.

I actually have the fog light wiring running through the actual fog light switch on the turn signal tree. The wiring harness was already there, tucked up and zip tied under the front fenders for each side.

I have a set of KC 55w slimline driving lights that was going to be my next project, would those be better than the Hella fogs, power wise?

When you say that they are wired together on the factory harness, do you mean they are sharing the same Hot wire as the Main headlights? I tried looking for a good wiring diagram but only found bits and pieces....



Thank you all for your feedback, It is what makes the Jeep community great
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Old 10-28-2012, 03:42 PM   #8
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Convert to hid bulbs.. Mine are bright as hell
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Old 10-29-2012, 06:11 AM   #9
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Quote:
Originally Posted by bandman View Post
So does anyone think that the same KC 55/60 replacement headlamps Akita listed would have had the same problem if the fog lights were these 55 watt replacement/plug and play KC hilights 1131 fog lights
KC HiLiTES 1131 - KC HiLiTES Replacement Fog Light for 97-04 Jeep Wrangler TJ & Unlimited - Quadratec
I have the same year jeep unlimited and was looking at the same upgrade. Don't want to fry my wires and leave me in the dark on the way to work!
IMO no I do not think there would be an issue. I am basing that on the specs for the lights and that those are "KC replacement Fogs" and are pretty much identical to factory spec wise.

My headlights were upgraded in '06 and the KC fog light replacement in '08....never an issue. Until the factory multifunction switch went bad. That is when I installed a relay and ran the wires for the fogs independent of the headlights/ or the key being in ignition.
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Old 10-29-2012, 06:32 AM   #10
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Quote:
Originally Posted by Unlimited-Akita View Post
I actually have the fog light wiring running through the actual fog light switch on the turn signal tree. The wiring harness was already there, tucked up and zip tied under the front fenders for each side.

I have a set of KC 55w slimline driving lights that was going to be my next project, would those be better than the Hella fogs, power wise?

When you say that they are wired together on the factory harness, do you mean they are sharing the same Hot wire as the Main headlights? I tried looking for a good wiring diagram but only found bits and pieces....



Thank you all for your feedback, It is what makes the Jeep community great
It could be the difference in the model years....but the part about "tucked up and zip tied on each side" makes me question if it already had been jacked around by PO. On my '04 that, I purchased in '04, the wire loom from fuse box under the hood, runs across the top of the firewall, and along the driver's side fender. And than the wiring when it reaches the drivers side headlight, turn signal, fog light area.

I would imagine Jeep did this to conserve wire only about 4 feet of wire but 4 feet x three lights, times a few 100,000 Jeeps...WOW!

The being wired together......IDK the exact correct terms, or exactly how it is done, but there is a relay that allows the factory fog wiring to only be on when the headlights are on low beam.

I think your original post said you had your HIGHBEAMS and FOGS on at the same time. While I have that ability now, and know that the "mod" has been discussed on here, I don't know if the factory wiring is "heavt enough" to carry that kinda of a load.....especially with the upgraded fogs. And IMO electrical will do some "funny things" when we start putting "too much juice", to smaller gauge wires.

IMO I would wire those big Hella's on their own dedicated circuit, and hope there is no permanent damage to the headlight wiring.

Seperate/ rocker toggle switch, relays and it's own complete harness. The factory wiring is just not up to the job for that big of a draw all the time.

I would do the same thing for the Slim lights, but honestly, I have the KC fog replacements, the headlight upgrade, and the slim lights myself, and each on its own circuit, headlights on factory circuit no other lights tied in.

But I rarely NEED all of them. I sometimes use slim lights without the fogs with headlights, but never have I needed all 6!!!

Good LUCK!!

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