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Old 11-13-2011, 10:46 AM   #1

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Headlights keep cutting out on my TJ.

My 99 TJ has been having a problem with the headlights since I purchased it last summer. Shortly after pulling the headlight switch to the on position, within about 5 minutes or so, all the lights, including headlights, dashlights, taillights etc...shut themselves off. I have to quick push the headlight switch in and out (sometimes twice) to get the lights to come back on.

It will only do this once until I shut the engine off, the next time I drive it after dark the same thing happens. It does not matter if I am driving on a dirt road or down the highway, so I'm not sure if it is a loose wire or what. I'm thinking it might be a bad relay switch, but I would like some input from the members who might have experienced the same thing to point me in the right direction.

Thanks Jeepers!

2012 Sahara Unlimited, Sahara Tan
1999 TJ SE, Black
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Old 11-13-2011, 10:58 AM   #2
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Hi, I had similar but not quite the same problems with my headlights. Some suggested ihad to change the light assembly but when I did spending about £60 it turned out to be the plastic wire connector block that plugs into the back of the light switch unit. it had become brittle and had melted slightly, a couple of the wire connectors were shorting and sometimes I would lose my headlights.

I couldn't find a scrap yard or anywhere to buy a new plastic connector block so I wired the spade connectors directly in, with insulation tape as they are close together.

This solved my headlights problem but now my indicators have stopped working, i'm working on that one.

Hopenthis he ps Shaun

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Old 11-13-2011, 11:05 AM   #3
Knows a couple things...

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The headlight circuit is very basic with just the headlight switch and no relays anywhere, just replace the headlight switch which is very quick and easy to do. My '97 TJ's headlights did the same thing and it was just the switch. Check for a melted connector too as suggested above by Lazsjs2000.
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Old 11-13-2011, 10:13 PM   #4

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Thanks guys, I pulled the headlight switch and it looks like hell, it looks like it is slightly melted in the back. I've already placed my order at quadratec for a new switch. Got some better headlights on order too, nothing fancy, but they should be better than the originals.
2012 Sahara Unlimited, Sahara Tan
1999 TJ SE, Black
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