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. .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"   you ask...  ..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 {f^{_{or 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 ..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.
 

 ***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    


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,   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

Edited July 14, 20159 yr by 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 dimm on bright, etc...

So not finding any information in relation to a possiable wiring diagram i purchased a HD "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..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 CRIMPPED AND "NO HEAT SHRINK:spend:

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 ..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.

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/

O.K Guys..Here is a Parts list complete with part numbers & prices. except for the fuse holders, I got all my parts from "Susquehanna Motorsports" http://www.rallylights.com phone# 1-610-944-3233

[*]1-male headlight connector (same as bulb)...............................................#CP9004CM..............7.49ea.

[*]4-Ceramic female 9004/9007 Connectors.......................................................#CP9004CFC.............7.49ea.

[*]4-HELLA Relays, 40A, Dual 87 outs, with Diode.............................................#HL87453...............13.22ea. Option" 4-HELLA Relays, 40A, Dual 87 outs, without Diode.............................#HL87453.................8.00ea.

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

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

In all of this i forget to mention," I soldered all my connections & used heatshrink tubing to make a moisture free system. I also harnessed all the wires in split wire loom conduit that can be found im most electrical stores and some parts stores such as Autozone and NAPA..

well..thats about it..Good Luck and remember "HAVE FUN WITH IT":thumbup2:

Richie

i have the lmc headlight harness on my truck. and what a peice of chinese junk! high beems will not dimm up or down. anyway i'm thinking of taking the lmc harness back off and replace it with this system. have a question i found all the other parts needed except the relays. i can't seem to find the 4-HELLA Relays, 40A, Dual 87 outs, with Diode #HL87453 Option" 4-HELLA Relays, 40A, Dual 87 outs, without Diode #HL87453 i can't find the part numbers for the relays on that website? is there any other relay that will work?

I've been studying the drawings and will attempt the harness myself. I have the same concern about the relay availability with diode.

- - - Updated - - -

If it goes well, I may offer harnesses for sale with heavy gauge wire, soldered connections and good relays. Seems nobody is happy with what's out there.

I've been studying the drawings and will attempt the harness myself. I have the same concern about the relay availability with diode.

- - - Updated - - -

If it goes well, I may offer harnesses for sale with heavy gauge wire, soldered connections and good relays. Seems nobody is happy with what's out there.

Let us know how it goes!

I've been studying the drawings and will attempt the harness myself. I have the same concern about the relay availability with diode.

- - - Updated - - -

If it goes well, I may offer harnesses for sale with heavy gauge wire, soldered connections and good relays. Seems nobody is happy with what's out there.

ok i found the relay at amazon i typed in IMPERIAL 87453 relay. they are expensive at $40 each. does anyone else know if there is any other kind of relay that i can use in this relays place?

I need to gather all the pieces and do this too.

ok i found the relay at amazon i typed in IMPERIAL 87453 relay. they are expensive at $40 each. does anyone else know if there is any other kind of relay that i can use in this relays place?

WTF???

Why not use a damned Bosch 30/40A relay (330-073), available most anywhere, for like $5-8 each? It's just a standard SPDT 40A relay.

I mean, here's a set of 5 Bosch-type 40A relays, with pigtails, for $15 free shipping..

http://www.ebay.com/itm/5-12V-BOSCH-STYLE-RELAYS-40A-SPDT-5-5-WIRE-SOCKETS-/300570729695?_trksid=p2047675.m1850&_trkparms=aid%3D222002%26algo%3DSIC.FIT%26ao%3D1%26asc%3D11%26meid%3D4708639855196558952%26pid%3D100011%26prg%3D1005%26rk%3D3%26sd%3D380518193546%26

It'll take a little different wiring up, but it'll save a helluva lot of money. And if a relay goes bad, replace it for a couple bucks.

I'm (personally) not one to spend 10x as much to have a dual out relay..

WTF???

Why not use a damned Bosch 30/40A relay (330-073), available most anywhere, for like $5-8 each? It's just a standard SPDT 40A relay.

I mean, here's a set of 5 Bosch-type 40A relays, with pigtails, for $15 free shipping..

http://www.ebay.com/itm/5-12V-BOSCH-STYLE-RELAYS-40A-SPDT-5-5-WIRE-SOCKETS-/300570729695?_trksid=p2047675.m1850&_trkparms=aid%3D222002%26algo%3DSIC.FIT%26ao%3D1%26asc%3D11%26meid%3D4708639855196558952%26pid%3D100011%26prg%3D1005%26rk%3D3%26sd%3D380518193546%26

It'll take a little different wiring up, but it'll save a helluva lot of money. And if a relay goes bad, replace it for a couple bucks.

I'm (personally) not one to spend 10x as much to have a dual out relay..

that is why i have not bought that one. i did find a 30 amp duel 87 pin relay at the local oreilly auto parts for like $5.00 each. witch i can live with. i got the inline fuse and the wiring and ordered the rest of the special wiring componets last night. please forgive me as i have never done any wiring like this before. i'm still learning. but i will check out that link you gave me. thanks

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thanks for that link. i just looked at it and thats just what i was looking for and bought a set.

has the duel 87 pin even. i can live with $14 that includes 5 relays with relay plug ins. that sure beats the other relays that were $40 each. now all i have to do is wait till all the parts to show up so i can start putiing the wiring harness togather.

that is why i have not bought that one. i did find a 30 amp duel 87 pin relay at the local oreilly auto parts for like $5.00 each. witch i can live with. i got the inline fuse and the wiring and ordered the rest of the special wiring componets last night. please forgive me as i have never done any wiring like this before. i'm still learning. but i will check out that link you gave me. thanks

- - - Updated - - -

thanks for that link. i just looked at it and thats just what i was looking for and bought a set.

has the duel 87 pin even. i can live with $14 that includes 5 relays with relay plug ins. that sure beats the other relays that were $40 each. now all i have to do is wait till all the parts to show up so i can start putiing the wiring harness togather.

Yes, they do have (2) 87 terminals, but they're not the same as the Imperial $40 relay.

The Imp relay is a SPST (single pole, single throw) with the same output coming out on both 87 pins at the same time.

The Bosch-type, like the 5-pack, are SPDT (Single Pole Double Throw). They, too, have (2) 87 pins, but they're 87 and 87a. How it works is that whatever is on pin 30 (be it GND or PWR) will be present on 87a when the relay is NOT energized. Once the relay is energized (12v on 85, gnd on 86, the presence will switch from 87a to 87.

So you'll need to compensate for that in the wiring diagram, which won't be hard.

Basically, ignore 87a. Use 87 as your input (fused 12V from source[battery]) and 30 as your output to the low and/or high beam lights. You can tag both low beam wires to the one relay pin.

:smart:Alright Rick, sounds like your the guy to wire these up for us dumbby's. I will buy a harness from you if you build me one.

:smart:Alright Rick, sounds like your the guy to wire these up for us dumbby's. I will buy a harness from you if you build me one.

Sure thing! Sent from my Amazon Kindle Fire using Tapatalk 2

:smart:Alright Rick, sounds like your the guy to wire these up for us dumbby's. I will buy a harness from you if you build me one.

I agree, whichever guy gets it done, I'd buy one too.

If I were to make these for you guys, it would most-likely have to be a "pre-paid" thing, as I am a single income family, and spare change is about non-existant.

But I'd be happy to make them. It would give me something to do these winter evenings.

I wouldn't charge much for my time. I'll price the current parts out, and factor in time, and give you a rough pricing for a harness kit, hopefully this evening.

- - - Updated - - -

Ok, you're looking at 'roughly' $110 in materials (connectors, wire, relays, fuses, etc.)

So about $140-150 shipped, depending on time involved..

Depending on pre-ordered quantity, I could roughly have these out (parts ordered to assembled/shipped date) in about 5-7 days. that's really almost free labor, once you factor in parts shipping to me, and assembled units shipped out..

Tips accepted LOL

I'm in! How do you accept payment?

I'm in! How do you accept payment?

Agreed - I'm in.

I can do check by snail mail, or paypal

PayPal works for me. Figure out your total and post up your Paypal address.

Yes, they do have (2) 87 terminals, but they're not the same as the Imperial $40 relay.

The Imp relay is a SPST (single pole, single throw) with the same output coming out on both 87 pins at the same time.

The Bosch-type, like the 5-pack, are SPDT (Single Pole Double Throw). They, too, have (2) 87 pins, but they're 87 and 87a. How it works is that whatever is on pin 30 (be it GND or PWR) will be present on 87a when the relay is NOT energized. Once the relay is energized (12v on 85, gnd on 86, the presence will switch from 87a to 87.

So you'll need to compensate for that in the wiring diagram, which won't be hard.

Basically, ignore 87a. Use 87 as your input (fused 12V from source[battery]) and 30 as your output to the low and/or high beam lights. You can tag both low beam wires to the one relay pin.

don't think i understand for this dummy. me being the dummy. still waiting for the sockets to show up from rallylights.com. been week and a half so far. they have not shipped it out no tracking number????? may call them to see whats up. can you make a wiring diagram for these relays? otherwise may just buy those other relays i'm not good with wiring. other option pay you to make up a wiring harness for me????

- - - Updated - - -

how about this one then?

http://www.rallylights.com/detail.aspx?ID=948

don't think i understand for this dummy. me being the dummy. still waiting for the sockets to show up from rallylights.com. been week and a half so far. they have not shipped it out no tracking number????? may call them to see whats up. can you make a wiring diagram for these relays? otherwise may just buy those other relays i'm not good with wiring. other option pay you to make up a wiring harness for me????

- - - Updated - - -

how about this one then?

http://www.rallylights.com/detail.aspx?ID=948

that's the one to use, if you need to save some wiring headache.

that's the one to use, if you need to save some wiring headache.

thanks rogan i did not know there was a differance between a spdt and spst relay. i learned somthing. i think i will go that route to make things easyer. as my wiring skills are limited. looks pretty simple enough just the relays were little confusing to me till you explained it. thanks for the help.

No problem buddy. :)Sent from my SPH-L710 using Tapatalk 2