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  1. #1
    Join Date
    Feb 2003
    Location
    San Bernardino CA
    Posts
    496

    Question Headlight relay kit...

    Can y'all give me some resources for a headlight relay kit? Also, some tips on how to install, or where to get the instillation instructions.



    Thanks in advance, Patrick.
    '93 D-250 LE, Patriot Blue, reg-cab, auto, 3.54 LSD, BHAF, Rebuilt VE @282k, 3" straight-pipe/24" Wickedflow, MagHytec covers, ARE lid matches hood, 308K, 133rwhp/311rwt , 17-25mpg, avg-20mpg.

  2. #2
    Join Date
    Apr 2008
    Location
    Bremerton, WA
    Posts
    639
    http://www.bigrigchromeshop.com/Merc.../LITWH/UP34263
    First relevant search I found on Google via another forum.
    Gives a decent schematic you could use to make your own. . .
    2006 Mega Cab Dually, Hand Shaker, BD Brake, 3.73 LSD.

  3. #3
    Join Date
    Sep 1999
    Location
    Riverside
    Posts
    10,481
    Install a relay at each headlamp. Just use the headlamp feed for the relay trigger



    http://www.bigrigchromeshop.com/Merc.../LITWH/UP34263

    First relevant search I found on Google via another forum.

    Gives a decent schematic you could use to make your own. . .



    That would do it
    Last edited by Bob4x4; 01-27-2013 at 10:29 AM.
    94 2500 4x4 5 spd Carli performance 2.0 with full leafs
    2005 2500 Quad 4x4 48re,Carli dominator 3.0 plus long travel air bags, Baja proven and enough power to make it work

  4. #4
    Join Date
    Jan 2002
    Location
    Lincoln, Maine
    Posts
    5,065
    Freightliner, Western Star and Sterling Dealers have a relay kit that include the wire ends, relay plug/bracket combo and the relay. We sell a pile of them.



    Part Number is 681 545 00 K1. Around $19. 00 each.



    Makes a nice clean reliable installation.



    Mike.
    2006 2500 4x4 Mega Cab SLT Auto 3.73's
    Inferno Red 122,000 Miles Jake Brake, Edge w/Attitude, MagnaFlow 5" Exhaust
    1997 2500 4x4 Reg Cab Auto
    2002 Chrysler T&C
    2008 Chrysler T&C
    2004 Cougar 290RKS 5th Wheel (I know, I know)
    2003 VW Jetta TDI (Gizmo)
    2006 Cadillac DTS Lux I (Hoopty)

  5. #5
    Join Date
    Mar 2003
    Location
    Ontario, Canada
    Posts
    2,921
    Sweet!! Thanks again for great into Mike! Will pick up one of these for the crew and maybe even a second for the 1990.
    President - Ontario Chapter TDR

    1990 Reg Cab W250 LE NV5600 6 speed, not so stock.

    1993 Crew Cab W350 Dually 97 12V NV5600 NP205 Dana 80 Kelderman Air ride Gear Vendors PDR Twins FASS Horton Fan

    2008 2500 Mega SLT 6.7 68RFE 4x4

  6. #6
    Join Date
    Mar 2003
    Location
    Ontario, Canada
    Posts
    2,921
    Sweet!! Thanks again for great into Mike! Will pick up one of these for the crew and maybe even a second for the 1990.
    President - Ontario Chapter TDR

    1990 Reg Cab W250 LE NV5600 6 speed, not so stock.

    1993 Crew Cab W350 Dually 97 12V NV5600 NP205 Dana 80 Kelderman Air ride Gear Vendors PDR Twins FASS Horton Fan

    2008 2500 Mega SLT 6.7 68RFE 4x4

  7. #7
    Join Date
    Jan 2002
    Location
    Lincoln, Maine
    Posts
    5,065
    Quote Originally Posted by BSchwarzli View Post
    Sweet!! Thanks again for great into Mike! Will pick up one of these for the crew and maybe even a second for the 1990.


    I cant find a picture of the contents on the web, I'll post a picture from work tomorrow of what it contains.
    2006 2500 4x4 Mega Cab SLT Auto 3.73's
    Inferno Red 122,000 Miles Jake Brake, Edge w/Attitude, MagnaFlow 5" Exhaust
    1997 2500 4x4 Reg Cab Auto
    2002 Chrysler T&C
    2008 Chrysler T&C
    2004 Cougar 290RKS 5th Wheel (I know, I know)
    2003 VW Jetta TDI (Gizmo)
    2006 Cadillac DTS Lux I (Hoopty)

  8. #8
    Join Date
    Aug 2002
    Location
    Indiana
    Posts
    2,231
    Does the factory switch have trouble with the amp draw over time?
    91.5 D250 LE
    Regular Cab, A518

  9. #9
    Join Date
    Sep 1999
    Location
    Riverside
    Posts
    10,481
    Yes the terminals and insulator take a beating when the switch gets hot
    94 2500 4x4 5 spd Carli performance 2.0 with full leafs
    2005 2500 Quad 4x4 48re,Carli dominator 3.0 plus long travel air bags, Baja proven and enough power to make it work

  10. #10
    Join Date
    Mar 2003
    Location
    Ontario, Canada
    Posts
    2,921
    Yeah. I have replaced about 4-5 of them in the 1990 in the last 10 years. . . . No trailer towing and no gauges allow them to last. If you do and have the two, then it's not looking good!
    President - Ontario Chapter TDR

    1990 Reg Cab W250 LE NV5600 6 speed, not so stock.

    1993 Crew Cab W350 Dually 97 12V NV5600 NP205 Dana 80 Kelderman Air ride Gear Vendors PDR Twins FASS Horton Fan

    2008 2500 Mega SLT 6.7 68RFE 4x4

  11. #11
    Join Date
    Jan 2002
    Location
    Lincoln, Maine
    Posts
    5,065
    Quote Originally Posted by mwilson View Post
    I cant find a picture of the contents on the web, I'll post a picture from work tomorrow of what it contains.


    Kit contains the holder, relay, wire ends and terminal lock for the holder.

    Another neat feature is that they will nest, you can hook several together using the built in tracks on the side of each holder.

    Very heavy duty, quality stuff. No flimsy light duty junk here.



    Relays are 50/30 amp rated.



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    Mike.
    Last edited by mwilson; 01-28-2013 at 05:33 PM.
    2006 2500 4x4 Mega Cab SLT Auto 3.73's
    Inferno Red 122,000 Miles Jake Brake, Edge w/Attitude, MagnaFlow 5" Exhaust
    1997 2500 4x4 Reg Cab Auto
    2002 Chrysler T&C
    2008 Chrysler T&C
    2004 Cougar 290RKS 5th Wheel (I know, I know)
    2003 VW Jetta TDI (Gizmo)
    2006 Cadillac DTS Lux I (Hoopty)

  12. #12
    Join Date
    Sep 1999
    Location
    Riverside
    Posts
    10,481
    Mike,that's about what I built my harness with but parts from Dodge
    94 2500 4x4 5 spd Carli performance 2.0 with full leafs
    2005 2500 Quad 4x4 48re,Carli dominator 3.0 plus long travel air bags, Baja proven and enough power to make it work

  13. #13
    Join Date
    Mar 2003
    Location
    Ontario, Canada
    Posts
    2,921
    Sweet! Thanks!
    President - Ontario Chapter TDR

    1990 Reg Cab W250 LE NV5600 6 speed, not so stock.

    1993 Crew Cab W350 Dually 97 12V NV5600 NP205 Dana 80 Kelderman Air ride Gear Vendors PDR Twins FASS Horton Fan

    2008 2500 Mega SLT 6.7 68RFE 4x4

  14. #14
    Join Date
    Apr 2008
    Location
    Bremerton, WA
    Posts
    639
    Just thought of something. If you are going straight from the battery to power the headlights, make sure it's fused. Also, consider reducing the rating of the factory fuse to match the relays that are now the only load.
    2006 Mega Cab Dually, Hand Shaker, BD Brake, 3.73 LSD.

  15. #15
    Join Date
    Sep 1999
    Location
    Riverside
    Posts
    10,481
    Quote Originally Posted by JHumphries View Post
    Just thought of something. If you are going straight from the battery to power the headlights, make sure it's fused. Also, consider reducing the rating of the factory fuse to match the relays that are now the only load.
    The headlights do not use a fuse,but you should use one to the relay from Batt
    94 2500 4x4 5 spd Carli performance 2.0 with full leafs
    2005 2500 Quad 4x4 48re,Carli dominator 3.0 plus long travel air bags, Baja proven and enough power to make it work

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