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    SPORT/QUAD HEADLIGHT CONVERSION

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    rburks

    OK Guy's.."The moment you've all been waiting for" Here is a complete start to finish Details on Converting Standard 2-headlight system to a Sport Quad headlight sys. i did a few months ago

    Let me tell you it was a P.I.T.A...i had nothing to go on as none of the threads i found on any of the forums involved building your own from scratch "w/Heavy Duty Stuff" ..most of the write ups were people who had bought a pre-wired harness..like the ones for example suvlights.com or others..all reported problems either "fog lights staying on..lights would not turn off, lights would not come on or lights were dim on bright, etc...  So not finding any information in relation to a possiable wiring diagram i purchased a "pre-made harness w/relays from LMC..What a piece of shi$$..i mean lets totally forget that it did not work,{ lights went out or "almost out on Dimm}...this was chineese junk a frigg'n fire hazzard. :cookoo:.cheap light gauge wire i could bite into. connectors that "pulled out after unplugged a time or two..and last but not least.."NO SOLDERED CONNECTIONS, ALL CRIMPED AND "NO HEAT SHRINK.

     

       See none of these aftermarket harness's will work on these Trucks neither the Chinese "JUNK" nor the other decent harness's...."WHY"  :shrug: you ask... :smart: ..Because no one { that i was able to find } has been able or have taken the time to "Crack This system" and build a precise fit "PLUG AND PLAY" HARNESS ".  The 2nd GEN Dodges have a ODD wiring system, I Call it {for lack of a better term} Ground Switching System because thats what it does. It switches the ground Neg-  instead of the POS+.. The original wiring has a hot wire to Headlight plug that HOT 24/7..all the time.

     

        SO..after tryin to get around it..I started designing & building my own system. and with much help from..MICHAEL "MOPAR MAN" i eventually completed my own system.."NOW..Im passing this information on to you guys because the lights on these trucks "SUCK"..and this is an Awesome improvment that....well :stuned:..you will have to see for your self.....AND......I DONT WANT NO ONE TO GO THRU WHAT I WENT THRU BUILDING MINE ..L.M.A.O. :smart::broke:
     

     ***note***  I soldered all my connections & used heat shrink tubing to make a moisture free system. I also harnessed all the wires in split wire loom conduit 

     

     

    thanks Michael   :thumb1: 


    Check out link below:
    Slideshow
    http://s1209.photobucket.com/albums/cc389/rburks1/Dodge%20Sport%20Quad%20Headlight%20Conversion/?albumview=slideshow

    Pictures
    http://s1209.photobucket.com/albums/cc389/rburks1/Dodge%20Sport%20Quad%20Headlight%20Conversion/


     Below is the Parts list complete with part numbers & prices. except for the fuse holders, I got most all parts from 

     you can find these parts at most auto or electronic's stores and they don't have to be these brands either but i suggest using quality relays w/holders to make replacement easy. 

     

       

     

    COMPLETE PARTS LIST for HD HEADLIGHT HARNESS (sport HL)

    ***note***  This Parts list is for reference only.. Vendor, Manufacture & Brands are open to your preference 

     

     

       2-male headlight connector (same as bulb)............................................#CP9004CM..............7.49ea.

     

       2- Ceramic female 9004 Connectors                                                       #CP9007CFC.............7.49ea

     

       2-Ceramic female 9007 Connectors.......................................................#CP9004CFC.............7.49ea

    .

       4-HELLA SPST Relays, 40A, Dual 87 outs, .............................................#HL87483...............8.00ea. 

     

       **Option**   4-SPST HELLA Relays, 40AMP, Dual 87 outs, with Diode.............................#HL87753..........13.00ea.   NO LONGER AVAILABLE    

       **Option**   4-SPST HELLA Relays, 30AMP, Dual 87 outs, with Diode..............................#HL87453..........8.00ea.     Available @ ralleylights.com

     

    ****** Note******* It is not mandatory to use the ones with diodes or resistors, it just helps insure safety for stereo sys, CB & The entire electronic system from EF Feedback.. You could use 30amp relays as you are using separate low and high beam circuits.

                    In the beginning i was originally trying to use only 2 Relays, 1 on each side. I found out later this to be "IMPOSSIBLE" . YOU MUST HAVE 4-RELAYS..  You can use ones with single 87 out and wire together,, the Dual 87 out just makes a nice clean wiring system and i hat cobbled up wiring

     

     

     

       4-Relay Holders, complete with terminals....................................................#HL87123.................3.77ea.

    I Strongly recommend using Holders, it will make changing a relay out as easy as changing a fuse if you should ever have to

     

      I got the fuse holders from Advance Auto....."Bussmann Inline, 12ga. wires............#BP/HUU...................5.49ea.

     

      

       

            I got the Dodge OEM Sport Headlight assembly's @ http://www.factorymopar.com they are a Dodge dealer with online OEM parts. there prices are way below local Dealership.

                                 Sport Headlight Assembly's  :

                                 price=  233.64.. left side

                                             225.38 ..right side

     

     There are Cheeper Options for the The Sport Headlights but be forewarned of the cheap knockoffs and there problems like "leaking", , not very good fitment or alignment, ,poor quality Adjusters that make adjustment difficult or impossible>>>

    "This is important cause you will have to dial these in and insure the Beam is to the left on LOW BEAM Driver side as to keep from blinding oncoming Cars.    "The OEM Lights are pretty close out of the box "..  

        A salvage yard would probably be a good source if you could find any thats not damaged.

     

       

                                          

     

     

     

    **UPDATE PLEASE READ **

       I have had several Guys PM me asking why is it that there HB indicator light stays burning even on LB...most of the time this issue is caused by wires being in wrong location on one of the Headlight plugs .  A weak GROUND circuit will also cause this,  :doh: You have to have a solid -GND circuit to the Headlight connectors. I used the spare Side post Terminal's on my OPTMA RED TOP BATTERIES POS+ & GND - post.  BUT: There is a Post on front inner fender just below the Battery, there is a Solid 8# wire that runs from there that goes to Neg- post  battery terminal on battery so this is as good as going straight to Neg without having a bunch of wires hanging off of your Battery causing mores battery issues in the future.. But first be sure it is solid and clean,, if not solid and free from corrosion then replace it.

     

    The other cause would be that you have a wire in the wrong place on the back of one or more H L connectors or in the conversion plug itself.

    Dodge sport Quad headlight conversion.doc

    Dodge Sport Quad Headlight Conversion- Relays.doc

    post-114-138698174449_thumb.jpg

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