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rburks

The moment you've all been waiting for "SPORT/QUAD HEADLIGHT CONVERSION"

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rburks    49
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

Edited by rburks
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Heavyd1980    1
Heavyd1980

man that is great work and im sure tough at times. thank you very much. but now i must ask a dumb question what is the difference in sport headlights from i guess the norm headlights?:shrug:

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Heavyd1980    1
Heavyd1980

ok so the low beam and high beam are seperate but are the corner lights seperate as well

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rburks    49
rburks
ok so the low beam and high beam are seperate but are the corner lights seperate as well[/quote

]]]]]]]]]]]]]]]]]]]]]]]]]]]]

Yeah..you dont mess with the corner/park lights

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dracozny    2
dracozny

man that is great work and im sure tough at times. thank you very much. but now i must ask a dumb question what is the difference in sport headlights from i guess the norm headlights?:shrug:

separate bulbs for high beams, clear lenses, much much better reflectors.

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Heavyd1980    1
Heavyd1980

thank you for that. i am looking to replace my hazed over broken crappy lights as well. no matter how much buffing i do they still dont clean up very well.

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flagmanruss    80
flagmanruss

Suggest this valueable information be stickied somewhere.

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oudive    0
oudive

Sup,I know this is a little on the old side........but...Was looking at the added photos and based off the one picture with the relays on the board and the one pig tail that connects into the OEM connection. What about the two pig tails that lead to the actual light? I am thinking that the two that lead to the light are connected to the relay?? Anyone got a picture of this setup with the leads that run from the relays to the actual headlight? Any help would be great. Thanks.oudive

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rburks    49
rburks
Sup,

I know this is a little on the old side........but...Was looking at the added photos and based off the one picture with the relays on the board and the one pig tail that connects into the OEM connection. What about the two pig tails that lead to the actual light? I am thinking that the two that lead to the light are connected to the relay?? Anyone got a picture of this setup with the leads that run from the relays to the actual headlight? Any help would be great. Thanks.

Yes, the leads go to the Relays..Here you go ...

oudive

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oudive    0
oudive

Sup,Thanks for the reply, but the pictures did not load up. I think I have the just of it. If you get a chance if you could try to paste the pictures again, that would be cool. Thanks again for the reply.oudive

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rburks    49
rburks

Sup,

oudive
Sorry about that, i cant seem to get them to cut and paste.. but here is the link.....

http://forum.mopar1973man.com/attachment.php?attachmentid=2362&d=1294190527.

:thumb1:.

--- Update to the previous post...

Here is the link for the Harness from the relay boards to the OEM headlight plug

http://forum.mopar1973man.com/attachment.php?attachmentid=2361&d=1294189937

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beren    3
beren

Thanks so much for the graphics. I don't have any Microsoft products so I had to take the files to work to open them, they won't show in OpenOffice. There's a great *free* pdf creation tool called CutePDF, just pick it as your printer and it spits out a nice pdf, or use OpenOffice or LibreOffice, they even have a nice free drawing app. Anyway, here is a universal version of your diagrams.[ATTACH]3624[/ATTACH]

Dodge Ram Sport Headlight Conversion.pdf

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derez    0
derez

thanks for the post. ive been wanting to do this.

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oudive    0
oudive

Hey,Just wanted to give an update. I did this sport upgrade and the wiring as described in this thread. Just to give a little background; I went from stock OEM to aftermarket 2 piece headlight with clear lens and retro fitted them with FXR projectors w/HID, then to the sport headlight. The sport headlight is the happy medium and easy to maintain. If a ballast or HID component went bad, no stopping at local auto parts store for new part. With this sport conversion, everything is pretty much easier to get. Light out put is great, and the whole wiring with relays is very easy to follow. If anyone ask me about headlight upgrades, this is where I am going to direct them. If your wanting to upgrade your lights, this is the ticket. oudiveSent from my iPhone using Tapatalk

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zack_76401    0
zack_76401

Building my harness now and have a quick question or two,1) What do diodes do? I see you listed 2 options for relays, one with diodes and one without. are they vital?2) What size/type fuses are you guys using on the hot wire from the battery? i have limited experience with electrical. The post said 40 amp relays soI didn't know if i needed to use 40 amp fuses as well???Thanks in advance.Zack

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Rogan    30
Rogan

Building my harness now and have a quick question or two, 1) What do diodes do? I see you listed 2 options for relays, one with diodes and one without. are they vital? 2) What size/type fuses are you guys using on the hot wire from the battery? i have limited experience with electrical. The post said 40 amp relays soI didn't know if i needed to use 40 amp fuses as well??? Thanks in advance. Zack

Diodes allow voltage to flow only in one direction only. This keeps voltages from "back-feeding" through and sending power to something that you don't want to receive power. 40A relay is just what the relay is capable of handling. so if you push 20A or 30A through a 40A relay, it will not heat up. as for fuse-size, that will basically depend on wire-gauge and end-device capabilities. But wire-gauge ampacity is where you need to look, first.. Roughly, if you're running a 30A device, you'll need a 25-30A fuse, and minimum of 12g stranded copper. I used to have the ampacity chart memorized (old job relied on it), but I've not used it in years..

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yelpel24    0
yelpel24

I wanted to say a sincere thank you for this post. My truck had the quad/sport headlights when I purchased it; however, unknown to me at the time they were wired incorrectly. This had caused my headlights to go out twice.:banghead: I "fixed" it (incorrectly) once, :doh: and this post saved me from a lot of wasted time and frustration. I had to tweak it slightly due to my truck having HIDs; however, essentially it was the same. Thanks again for the great post!

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joecool911    275
joecool911

Not sure I'm up to this project myself? I'll study some more. Anyone around here interested in building me a harness? If you've been through the process it would be easier than going the learning curve. Heck of a way to start here on the forum for my first post. Lol.

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jmerritt    0
jmerritt

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.: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 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 :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:

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?

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joecool911    275
joecool911

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.

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Pondsy    4
Pondsy

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!

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jmerritt    0
jmerritt

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? :wow::pray:

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