Headlight switch melted
08-23-2015, 06:04 PM
#16
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Location: Prescott, Az
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Year: 1990
Model: Cherokee (XJ)
Engine: 4.0
I have same problem.just found the connector pigtail at O'Reillys for 40 bucks (ouch!) Haven't tried it yet,but it is 9 pin part # BWD PT351 a new 40 amp headlight to headlight wiring harness with relay is available on eBay for less than 19 bucks.relay connects directly to the battery and uses the headlight switch to simply switch on the relay,thereby preventing future heat overload.
Good plan with the harness though.
12-14-2015, 06:42 PM
#18
Member
I just bought that same pigtail from Lordco in Vancouver and it was $64! (of course, that's $CDN 
)
Also, the connector is not exactly the right for an 89 Cherokee but it's working (so far) -I had to cut off part of the plastic connector body that contained 2 lugs that don't fit in the 89 Cherokee light switch (I saw that tip in a YouTube video which I can't find now). Pretty simple install overall - the biggest issue was having to take the instrument cluster out in order to get enough access to the original connector/wires to solder in the pigtail.
)Also, the connector is not exactly the right for an 89 Cherokee but it's working (so far) -I had to cut off part of the plastic connector body that contained 2 lugs that don't fit in the 89 Cherokee light switch (I saw that tip in a YouTube video which I can't find now). Pretty simple install overall - the biggest issue was having to take the instrument cluster out in order to get enough access to the original connector/wires to solder in the pigtail.
Last edited by Bucko; 12-15-2015 at 03:08 AM.
12-17-2015, 07:14 PM
#19
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Location: Volcano, HI
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Year: 1992
Model: Cherokee
Engine: 4.0L HO
Headlight switch melted
my original post was in 2012 (!!!) and i never did find a harness to replace with. i ended up bypassing the connector with insulated female spades, crimped and soldered, with an extra heatshrink and it is still working great. I also put on the putco harness the same time and everything is working great since.
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