Kaiserman Posted December 27, 2023 Share Posted December 27, 2023 Plug melted on my 88 and I lost parking/tail/gauge lights. Did a quick look around and can only find 92+ plugs. Does anyone have a good PN for the 91- connector? Thanks. Link to comment Share on other sites More sharing options...
eaglescout526 Posted December 27, 2023 Share Posted December 27, 2023 Are you talking the one on the dash? If it’s the dash, new ones should be made. 84-96 they were the same. Now if it’s the front headlight connector behind the drivers side headlight, i don't know if anyone knows that connector name. Link to comment Share on other sites More sharing options...
Kaiserman Posted December 27, 2023 Author Share Posted December 27, 2023 Sorry, yes that should have read headlight switch plug. I changed the title. No one lists a connector for 91 and older. I had read online the 92+ are a little different. Link to comment Share on other sites More sharing options...
cruiser54 Posted December 27, 2023 Share Posted December 27, 2023 Do you want the connector with the wires in it or not? Link to comment Share on other sites More sharing options...
Kaiserman Posted December 27, 2023 Author Share Posted December 27, 2023 Can't hurt to have some wires with it. Mine look ok but I was wasn't able to get a great look at it last night. Need to pull the lower dash for better access. Link to comment Share on other sites More sharing options...
cruiser54 Posted December 27, 2023 Share Posted December 27, 2023 Those are available for about $55. Link to comment Share on other sites More sharing options...
Kaiserman Posted December 27, 2023 Author Share Posted December 27, 2023 1 hour ago, cruiser54 said: Those are available for about $55. Any chance you have a PN? I can't find any listed for 91 and older. Link to comment Share on other sites More sharing options...
schardein Posted December 28, 2023 Share Posted December 28, 2023 Looking at pictures on Rockauto, it looks like the 92 switch has two additional terminals that are not present on the 91. But other than that, the remaining terminals look to be the same layout. So, one could assume the 92+ connector would work. But I would bet $1 that they changed something about the switch or plug so it doesn't work. This one on Summit Racing doesn't cross reference, but it sure looks like it would work. Link to comment Share on other sites More sharing options...
schardein Posted December 28, 2023 Share Posted December 28, 2023 I want to add- look at the tabs on the switch body that the connector locks onto. On the 91, the locking tab on the top is towards the rear. The locking tab on the bottom is towards the front. That matches the Crown J3205596 connector. The 92 switch, it's hard to see, but the locking tabs are in reversed positions. Link to comment Share on other sites More sharing options...
schardein Posted December 28, 2023 Share Posted December 28, 2023 I've got a switch from a 79 J10 in front of me. To me it looks identical to the 1991. The Crown part on Summit cross references to the 79 J10. The only difference is how it interfaces with the mount at the dash. The J10 has a elongated snout that sticks out. The XJ one doesn't. That won't affect the connector. Link to comment Share on other sites More sharing options...
gogmorgo Posted December 28, 2023 Share Posted December 28, 2023 Almost ten years ago I got a part number off here. Don’t know if I ever wrote it down but if I found it once I can find it again. There we go. The rockauto link even still works. I’ll reiterate what I said in 2016 that I did need to trim a connector pin or two off the outside of the plug for it to fit, and you’ll probably want to figure out what needs trimmed before installing it on the headlight switch. I won’t necessarily stand by my explanation of what happens to the switch/wiring. I didn’t reread it because it’s pretty longwinded but I know I’ve had some misconceptions in the past. My current understanding is that the switch contacts arc and burn slightly every time you make a connection, which leads to a poor connection between switch contacts that gets very hot and conducts heat away to things that should not receive heat. Installing a headlight relay harness will alleviate the risk of recurrence. It also may increase headlight brightness. There is also potential for it to interfere with DRL functions if you have a Canadian spec truck, but that can be addressed very easily if need be. Link to comment Share on other sites More sharing options...
Kaiserman Posted December 29, 2023 Author Share Posted December 29, 2023 I ended up with a used one. I was curious if a 79-86 FSJ plug would fit. All of my FSJ' plugs are for the older 63-78 switches though. I'd still like to find a new one just to toss on the shelf. Hoping to run the winter with just a new plug before upgrading to the relay set up for the lights. Link to comment Share on other sites More sharing options...
Strokermjcomanche Posted December 29, 2023 Share Posted December 29, 2023 https://comancheclub.com/topic/49695-melted-headlight-switch-and-connector/ Link to comment Share on other sites More sharing options...
Kaiserman Posted January 6 Author Share Posted January 6 So my used one was melted as well. Just not bad enough to be obvious when it was still on the switch. If anyone is interested in knowing, the plug is the exact same as the 63-7? full size Jeeps. I happened to have one right on my bench in the garage. It was only very slightly melted. Almost like this is a common thing with Jeep, right? Link to comment Share on other sites More sharing options...
cruiser54 Posted January 6 Share Posted January 6 Hence this: CRUISER'S MOSTLY RENIX TIPS HEADLIGHT HARNESS UPGRADE NOVEMBER 17, 2015 SALAD 65 COMMENTS EDIT It’s easy to install a supplemental headlight harness. From the factory, the voltage to the headlight bulbs travels from the battery, through connectors, inside the cabin, to the headlamp switch, and then back out to the lamps via undersized wire and more connectors. It’s not uncommon to find only 10.5 volts at the lamps. The supplemental harness is installed so that it provides battery voltage to the lamps and is just triggered by the factory wiring. The result is about 35% brighter headlamps and headlight switches that don’t melt and burn out. Ebay has the harnesses. 2 headlamp H4 with ceramic connectors is what you want. You’ll likely be warned that the harness won’t fit your Jeep. It will. Absolutely plug and play: Remove grille and headlamp bulbs. I fed my harnesses from the passenger side starting between the battery and the back of the headlamp housing, over to the driver side. Plug the driver side bulb into the new harness. Attach the new harness’s ground wire under one of the small bolts on the radiator support after scraping the paint off under it. Attach the harness to the existing harness behind the grille working toward the passenger side. Plug the new harness plug into passenger headlamp. Plug original headlamp plug into receptacle on new harness. Attach the ground for the passenger side just like you did the driver side under a radiator support bolt. Attach relays with provided bracket on the passenger side inner fender. Connect power wires to battery. Link to comment Share on other sites More sharing options...
Pete M Posted January 6 Share Posted January 6 one of the best upgrades for the old Jeeps Link to comment Share on other sites More sharing options...
schardein Posted January 7 Share Posted January 7 2 hours ago, Kaiserman said: So my used one was melted as well. Just not bad enough to be obvious when it was still on the switch. If anyone is interested in knowing, the plug is the exact same as the 63-7? full size Jeeps. I happened to have one right on my bench in the garage. It was only very slightly melted. Almost like this is a common thing with Jeep, right? Yep, the Crown J3205596 connector is an exact fit. No need to go through the nonsense of modifying the later connector (WVE 1P1190, Standard Motor Products S720). Link to comment Share on other sites More sharing options...
cruiser54 Posted January 7 Share Posted January 7 Link to comment Share on other sites More sharing options...
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