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Factory Fog Light Switch & Brighter Lights

#1 User is offline   YJWhenUCanTJ 

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Posted 16 August 2005 - 02:27 PM

I replaced my factory fog/driving lights on the Rubi today with a set of 12V/120W PIAA's. I used the factory switch (on the turn signal stalk) and relay (in the fuse box under the hood). I removed the fuse box, exposed the bottom end (the fuse box, not mine) and replaced the factory 14g lead wire to the lights with 10g wire. I also used 10g wire for the grounds. Now instead of having 24W driving lights (yes, OEM driving lights are only 24W!!!), I have 120W driving lights without adding any additional switches. I also left the factory harness intact and ran new wire to the lights. Now I just hope it doesn't go up in flames. :nerd:
David M.
2003 Sport
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#2 User is offline   YJWhenUCanTJ 

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Posted 16 August 2005 - 04:34 PM

I know, it's not anything ground breaking, but getting rid of those awful 24W factory lights was a real delight.
David M.
2003 Sport
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#3 User is offline   Jim B 

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  Posted 16 August 2005 - 04:41 PM

Hey David, I like this idea, no idea is ever too small in my book. :ya: I would like to see pics of the wiring or at least color code used if it's not too late. :nerd: This can also come in handy for the stock wiring plugs onthe stock fog light that comes standard on the TJs with the switch on the dash.
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#4 User is offline   Jack H 

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Posted 16 August 2005 - 08:10 PM

Dave, instead of changing the wire size why not use the lead from the fuse box to activate a relay that has larger gage wire?
Jack
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#5 User is offline   YJWhenUCanTJ 

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Posted 17 August 2005 - 07:52 AM

Jack, that's effectively what I did. The factory wiring from the switch (on the turn signal stalk) to the fuse relay in the fuse box was not changed. This wiring is adequate to activate the relay. What was needed was a larger wire that delivered the voltage to the lights. The factory wire that ran from my fuse box to the lights was 14 AWG, good enough to make an engineer happy using a 24 Watt bulb (x2) but not good enough for a 120 Watt bulb (x2).

What would have helped, but I didn't think this mod was worthy enough of a write-up, was a picture of the modification I made at the fuse box. After disconnecting the battery cables from the battery and the fuse box, I lifted the fuse box out of the holders and removed the fuse box's bottom cover. This allowed me to remove the existing 14 AWG wire that is the lead wire going to the factory lights. I removed the fog light fuse so I could push out the factory fog light lead wire connector in the fuse box. I cut off the wire connector on the end of the factory lead wire, pried it open and crimped it to my new 10 AWG lead wire then pushed the wire connector back into the fuse box from the bottom. I replaced the fuse and put the fuse box back together.

At this point it was just a matter of running the new 10 AWG wire to the lights, getting a good ground, taping over the connectors, putting the wires into some left over black plastic wiring loom and wire tying things out of the way. So I really did use the factory wiring to power the factory relay/fuse. All that was needed was to give the new lights the correct gauge lead wire for the power draw. At least it sounds good doesn't it? :nerd:
David M.
2003 Sport
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#6 User is offline   hiway 

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Posted 17 August 2005 - 05:43 PM

So, I assume the factory relay is heavy enough....?
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