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No headlights!! low voltage

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Old 12-10-2013 | 09:45 PM
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Default No headlights!! low voltage

So I got around to testing my 99's electrical problems recently.
I lost my power locks and my headlights, highs and lows.
I have aftermarket projectors and 100/55 h4 bulbs hooked into factory wiring. This was installed by the PO.
Went out and tested the headlight connectors and am getting 6.3v with key ON engine OFF and ~7.3v with engine running.

I've replaced the headlight switch twice.
clean ALL grounds
I have my grill and front end all apart inspecting wires couldn't find anything that looked burnt or damaged.

My battery gives 12v with engine off and 14.5v at idle

Help me out guys I have had the worst luck lately with my jeep

Running lights, turn signals, and brake lights all work
Old 12-10-2013 | 10:01 PM
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You should replace the wiring to one of the re-routed harnesses It's really easy & will prevent future problems. Also have you checked your fuse box?

http://www.jeepforum.com/forum/f11/f...6/#post1772776
Old 12-10-2013 | 10:35 PM
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Might try running a wiring harness for the headlights, you could have burned the stock wiring up somehow and with ~6v's you should be able to trigger th relays on a wiring harness to turn on. Its a cheap, possible fix.
Old 12-13-2013 | 11:11 AM
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It's gotta be somewhere in the wiring. I'm really at a loss and sick of dealing with it

Weird thing is the fogs(rock lights) and all other lights work just fine
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Also noticed that my "high beam indicator" was slightly lit. And when I turned them on(or tried to) the light would brighten like normal.
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Old 12-15-2013 | 09:30 PM
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Probably gonna go ahead and get the Putco wiring harness.

Anybody know if 6.3v~ is enough to trip the relay? It's also 7.5v when running
Old 12-17-2013 | 11:55 AM
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Sigh :/
Old 12-17-2013 | 12:44 PM
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I wouldn't trust it. DRLs which are about 30% normal voltage isn't, constanty feedig too low of a coul voltagr can kill those relays.

You really should figure out what's causing this poblem though dude. Have you looked at the multifunction switch that activates the high beams? I don't see any mention of voltage anywhere other than the bulb sockets. What about at the switches?
Old 12-17-2013 | 09:29 PM
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Ok you're right. I have replaced the multifunction and headlight switches.
Ive chased some of the wires from behind the grill but couldn't find any damage.
What color wires am I looking to test at the switches so I can find where I lose voltage? And where can I trace them to?
Old 12-17-2013 | 09:39 PM
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These two should help you out:


Old 12-17-2013 | 09:50 PM
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Thanks salad! that'll take me a minute to look over but..

The PO had the factory fog lights hooked up to some cheap off road lights. I used these wires when I took them off to hook up my LED rock lights. Is it possible there is an inline fuse he added? I did cut off a lot of spare wire he had. It was all taped up but could've had one in it I never looked.
Old 12-17-2013 | 09:52 PM
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Maaaaaaaybe. Here are the fogs

Old 12-17-2013 | 10:26 PM
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Not sure if it was in the info that salad provided, but check the large connector inder the airbox, they are known to turn green and fuzzy, all of your front end lighting goes though this connector
Good luck!
Old 12-17-2013 | 10:33 PM
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Good point - that's C100 up there
Old 12-17-2013 | 10:43 PM
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Originally Posted by 831xj
The PO had the factory fog lights hooked up to some cheap off road lights. I used these wires when I took them off to hook up my LED rock lights. Is it possible there is an inline fuse he added? I did cut off a lot of spare wire he had. It was all taped up but could've had one in it I never looked.
Anything is possible. Who knows what the PO did? It doesn't sound like good workmanship, so I suggest you have three projects which go hand in hand.

  1. Clean up the PO's wiring mess. Redo it completely, and do it right.
  2. Install a harness for those high-current lights. Even if your stock harness were in perfect shape, you should do this.
  3. Find out what your problem is. You aren't going to fix this just by adding a harness.


I don't think you'll be out of the woods until you do all three.





Also, where are you measuring this voltage? You might have some bad grounds.
Old 12-17-2013 | 11:07 PM
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I removed a bunch of grounds and cleaned em all shiny also.
Im measuring at the connector check the pic.

The PO did a nice job on the wiring. He just had excess wire for the off road lights.
I don't have the off road lights any longer


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