[bradleyheathhays]

So I put a headlight wiring kit from LMC Truck on my '96 Cherokee that circumvents the normal wiring and runs the headlights directly off the battery by way of a relay. The kit runs the lights at 55/100 (low, hi) watts instead of the original 55/60. One reason I did this was because the light output was terrible, and the other was because for some unknown reason the headlights would shut off after being on hi for a bit. Never did this on low. I've had the new wiring kit on for a few years now and it seems to have solved the issue.

The problem I'm having now though is that this new harness is melting at one of the connections...

You can see only one of the wires is overheating while the other seems to be ok. I'm guessing the hot one is used by the high beams.

What could be causing this? Could it be related to why the high beams used to shut off before I replaced the wiring harness? A while back I asked about the shutting off issue on a number of Jeep boards but nobody had heard of this particular problem before.

 

[Melatv]

Hi: I would say you have a bad connection, which is causing the over heating -- just cut the connector off and solder the wires together and tape them up.

 

[mrbb]

or maybe need to upgrade wire size to handle load better!

 

[Jeepwm69]

I think I would run bigger wire, and eliminate that connector.

Relays are a great and cheap upgrade for lighting. Daniel Stern's website has some good info on it.

I did it to my CJ's headlights a long time ago.

 

[LedFTed]

acid

that picture, shows a lot of acid. sulfuric, and wire's that have been ate up by this. just saying.
sooner or later, maybe sooner, ya need cable not corrupted by too much acid. the acid can go way back into a cable.. worst i seen, 4", or more down a battery cable. it happens.. way more than 4". i have to dwell on it for a bit, for i can say for sure.

i thought about it a bit,, the acid can go way further than 4", inside a cable. perhaps. the furthest i eve cut into a cable was 8" down., or more before i trashed the cable