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[mattyspr]

At last I have found the problem with my headlamps (96P XJ pre facelift 2.5TD Limited) 

Its a burntout connector block on the headlamp pull switch, caused by water leak from windscreen seal 

Just wondered if anyone has any tips on changing this connector block. I suppose its a dash out job to get easy access?

Anyone have a spare block and pull switch they would like to swap in exchange for some beer tokens? 

Cheers all. Im off now to enjoy the rest of the weekend ....

Keep smiling .... It will soon be christmas 

[Dave69]

dash out i'm afraid well the wood facia and clocks are all that needs to come out. the switch has a small crew on bezel from the pull side and a push button to release the actual plunger which is a pain as it's on the underside of the switch. the switch itself is well packaged in a small space and the amount of loose wire to it is not alot. expect a scraped knuckle to start with and there is a single earth (?) cable towards the back of the switch itself.

no spare i'm afraid but when you have done it get two relays and fit those into the light electrics to take the load off the switch. look on the site go jeep as there is a good write up on how to do it



http://www.go.jeep-xj.info/HowtoHeadlightLoom.htm

[Panic mechanic!]

where are you ?

[mattyspr]

Im in Wolverhampton.

Think Im gonna change the switch n the the connector block. For starters. Then I think I'll give the headlamp loom the overhaul given on above reply. This looks a good option. Especially as my plan is to put some additional spots on the front of the old XJ

Think next weekend is the time to do it. As well as service the old gal and refit the EGR Turbo.

As well as the switch & connector block, can anyone guide me where the best/cheapest place is to get a 30amp and 40amp relay, 5 pin, as shown here........
[attachment=1]

This new jeepy thanks all for their help.........

[captain cavalier]

get your relays and connectors from maplins

done this conversion on mine and ran earths straight back to battery for both lights.

lights now 20-30% brighter

[Panic mechanic!]

I am close to J4 M5 and breaking a cherry if you need any bits, my only prob at the moment is getting time to take the bits off but if you need anything  send me a pm and we can try to sort something out.

[mattyspr]

Cheers Panic

I did try sending you a PM. Let me know if you got it. Laptop crashed as I pressed send and its not showing in my outbox

[Panic mechanic!]

I got it going to check the jeep tomorrow and see what on there from your list and I'll pm you back

[mattyspr]

Locating a replacement connector block is becoming difficult.

I suppose I will have to bite the bullet and go speak to my local jeep dealer and see what ridiculous price they come up with for a block, thats if they do them seperate to the harness

I will be doing the above DIY loom mod. So is it viable to remove my connector block and go just for individual spade fittings to the back of the switch?

This switch will only be used for switching a relay rather than powering the lamps.

Is this an option or is just too schoolboy like ..... 

Cheers all

[Panic mechanic!]

ok sorry I haven't had chance to get back to you mate but if you are doin nothing Sunday pm me a contact number and your welcome to come down and get  what you need off this xj here.