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1978 CJ7 V8 AMC20 D30 T150 Dana 20,4" lift,33" BFG KM2's,Detroit Lockers front & rear,4.10 gears,1 piece axle,Warn 9.5 XP Winch,Hi-Lift X-treme on the hood,Warn Rock Crawler Frt. & RR Bumpers,Warn Rock Crawler Tire Carrier,Supertop
1978 CJ7 V8 AMC20 D30 T150 Dana 20,4" lift,33" BFG KM2's,Detroit Lockers front & rear,4.10 gears,1 piece axle,Warn 9.5 XP Winch,Hi-Lift X-treme on the hood,Warn Rock Crawler Frt. & RR Bumpers,Warn Rock Crawler Tire Carrier,Supertop
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thanks Pete.. Im gonna start getting them built beginning of next week. If any one is interested please let me know. Im also gonna see about cleaning up the post or starting a new one to post pics of the harness and workmanship.
HAd a guy from a local site get back with me one his power output after the install. He was showing 11.2 low and 10.6 high at the socket. After installing the kit both sides went to 14.6.. as you can see from Mr.Sterns chart that just double and almost tripled his light output. Says his lights went from dim Yellow to bright white.
I figured Id post my new set of directions to show that its a very simple upgrade. IF you can chage a battery and your head lights the instalation is easy.. and thanks to Pete for the pics.
Step 1- remove positive cable from battery
Step 2 - Remove both head lights
Step 3 - Run wire through hole in grill below the head lights. Manuever the drivers side wire all the way over. Wire is long enough to be run along the bottom of the grill. If you have AC you can zip tie the new wires to the stock wires that run across the top of the grill. Position the sockets into the holes.
Step 4 - Plug the original passenger side head light socket into the new black female socket from the harness. This can go through the hole pictured or through the hole in the back of the grill.
Step 5 - Route the wires the way you like and secure them.
Step 6 - Reinstall both head lights.
Step 7 - Connect the 2 fused wires to the battery side (constant hot) side of the solenoid.
Step 8 - Connect the negative wire to a good groung source. I reccomend the engine block or negative cable on the battery.
Step 9 - Mount the relays and fuse holders. Try to mount them as high as possible to prevent excessive exposure to water.
Step 10 - Reconnect the positive cable & verify operation.
Trouble shooting.
Bad Ground - The only issue Ive had reported so far with this system is bad ground to the fender causing the relays not to groud and work. I have started building the harness with the relay ground included in the main ground wire to resolve the issue.
Bad fuse - I install a 10 and 15 amp fuse in the holder prior to shipping. Verify that they are seated correctly and in working order.
Bad passenger side head light socket - IF the head light socket is damaged or not getting power the relays will not turn on. Please verify with multi meter or test light that there is power going to the socket leads.
If you install the system and there is any issue feel free to call, text or email me and I can try to trouble shoot the problem over the phone.
Right now, only one '76 CJ5. 304 with a three speed stick. Everything else is pretty much stock 'cept for a 4" suspension lift. Came to me with a back breakin' 4" suspension lift attached to a reverse shackle setup (Reversed the reverse shackle :dung: and now she rides like a Caddy!) Also posess a few 60s & 70s Mustangs and a couple of late 70's F150s 4X4s.
Folks, if you haven't installed this harness in place of your original wiring setup, the least I can say is you are missing out on one of the best upgrades you can do for yourself and your Jeep. Just finished installing mine and took it for a spin in the dark. Amazing results!
I spent about an hour and a half installing mine. Figured I'd tidy up and re-route some of the wiring while I was under the hood. Tested the lights while I was still in the shop. I guess the original passenger side bulb lasted about two minutes before it popped and went dark. Quick trip to Wallyworld and picked up two new Sylvania's. Just the stock bulbs, not the high speed, low drag Xenon or other high dollar bulbs. Got 'em installed, turned them on and WOW! Ten times more light than before! I can actually see everything like I'm supposed to now. Wish I had done this years ago.
Jim is the man!! Cudos, reps and many thanks for providing this well needed product. Probably going to be giving you a holler soon when I bolt on my KC's and fog lights. Your price can't be beat and your quality of work is exceptional.
Very well done and probably the smartest $60 we can invest in a CJ. A similar upgrade is available for many motorcycles as they suffer the same issues. It worked wonders on my Ducati.
Taking Jimbo up on his offer to test one of these out was definately one of the smarter desicions I made for my Cj. Glad to see you were impressed as I was. I'll have to get one for the Limited soon. I'll be driving that one during the Winter. It may be dark when I leave for work and dark when I get home then, but I'll see fine.
Folks, if you haven't installed this harness in place of your original wiring setup, the least I can say is you are missing out on one of the best upgrades you can do for yourself and your Jeep. Just finished installing mine and took it for a spin in the dark. Amazing results!
I spent about an hour and a half installing mine. Figured I'd tidy up and re-route some of the wiring while I was under the hood. Tested the lights while I was still in the shop. I guess the original passenger side bulb lasted about two minutes before it popped and went dark. Quick trip to Wallyworld and picked up two new Sylvania's. Just the stock bulbs, not the high speed, low drag Xenon or other high dollar bulbs. Got 'em installed, turned them on and WOW! Ten times more light than before! I can actually see everything like I'm supposed to now. Wish I had done this years ago.
Jim is the man!! Cudos, reps and many thanks for providing this well needed product. Probably going to be giving you a holler soon when I bolt on my KC's and fog lights. Your price can't be beat and your quality of work is exceptional.
1978 CJ7 V8 AMC20 D30 T150 Dana 20,4" lift,33" BFG KM2's,Detroit Lockers front & rear,4.10 gears,1 piece axle,Warn 9.5 XP Winch,Hi-Lift X-treme on the hood,Warn Rock Crawler Frt. & RR Bumpers,Warn Rock Crawler Tire Carrier,Supertop
Have another question for you.... My son has a S10 and they suffer from the same problems as our CJ's do,low voltage.
He has the same terminals at the headlight,I believe they are called the H4/9003 (?),as ours.
Is there any reason why your kit wouldn't work on his S10 ?
Have another question for you.... My son has a S10 and they suffer from the same problems as our CJ's do,low voltage.
He has the same terminals at the headlight,I believe they are called the H4/9003 (?),as ours.
Is there any reason why your kit wouldn't work on his S10 ?
Nope not at all.. Im working on a webs site that has all the harness's I make with thier dimensions and spots for all the ones I can make. If you want me to make one for your some I need some measurements.
First thing to do is find a good place to mount a 3x3 square for realys. within 6" of that there needs to be a place to mount a 3x4 sqaure of fuse holders. From there I need to know
#1 - length from fuse holder to power source. It can be a open lug on in the fuse box under the hood if he has one there, starter solenoid lug, or from the battery terminal. Shorter the run the better
#2 - Length of wire from the relays to the passenger side headlight
#3 - length of wire from the relays to the drivers side head light
#4 - Ground wire length from the relay to a good ground source
It would also be nice to know how the wires will be run, either through the core support or around it. I send me a sketch with measurements and I can give you a price for it. I can also leave the hot wire and negative wire with out the ring terminals and a little bit longer so you can cut it down to the length you need.
Ill try to get a sketch of the length of my current CJ harness to see how it compares. I dont think it will be much longer then the FSJ harness I build.
Id like to build them for any thing that uses the H4/9003 plugs. Im gonna look at a TJ this week to see about setting one up for that.
1978 CJ7 V8 AMC20 D30 T150 Dana 20,4" lift,33" BFG KM2's,Detroit Lockers front & rear,4.10 gears,1 piece axle,Warn 9.5 XP Winch,Hi-Lift X-treme on the hood,Warn Rock Crawler Frt. & RR Bumpers,Warn Rock Crawler Tire Carrier,Supertop
Thanks Jim,I have passed your post on to my son. Figured you wouldn't have a problem doing it.
I'm very close to having the info you need to make one for my CJ7 too.
Glad to see you were impressed as I was. I'll have to get one for the Limited soon. I'll be driving that one during the Winter. It may be dark when I leave for work and dark when I get home then, but I'll see fine. 
