1996 Ram 2500 4x4 SLT.
Like so many others, my headlights started going out right when you need them, on the interstate in the middle of the night. It didn’t like the high beams particularly.
Read up on the subject. Bought a new headlight switch with the repair harness / connector after seeing so many pics of molten connections and wiring. The switch in my truck has already been replaced and the harness looks like it just left the factory in Mexico.
So I’m getting around to some deferred maintenance before a trip and figured I’d address some issues.
I’d installed the relay set up in my Gen1 and it worked like a charm. I’ve got the parts to do this truck and after putting the switch back in, I’ll install the relay mod.
is there a good spot to pick up the headlight wiring for three relays on the Gen2?
Kind of tight with dual batteries, figured I’d bypass all the factory wiring and install new.
if someone has done this on a Gen 2 (I know you’re out there) I’d appreciate any tips to make the job easier.

 

I'm not sure what you're asking in regard to "a good spot". I converted my '96 to the Sport (dual bulb) headlights and got relay harnesses (one for each side) from a company that has since closed. My harnesses use the OE wiring harness as relay triggers, so it plugs in between the OE headlight connector on each side and the lights, and to the batteries for power.

Can you post a pic of yours?

 

Well, I'm assuming that the high and low beam wires go from the switch to the driver's side headlight first (like on my Gen1) and that I can cut them right there and wire them straight too the relay coils.

 

I hear what you are saying regarding the load on the headlight switch on the gen 2's, mine gets pretty warm. I haven't noticed since I installed a britebox but will try to remember to check it out.

Similarly, I added back up lighting way back and still have the incandescent bulbs back there. To reduce the load on the wiring I just hung a relay behind the tail light and triggered it off the back up bulb and wired the lights to the 7 pin hot wire for good voltage back there...

I think your plan may work. I attached the britebox relay box to the rh battery tray wall, there is some room there on the front IIRC...

Kurt

 

^ ^ ^ ^ ^ ^ Does the britebox help eliminate the headlight switch on an 2001 from burning up?

 

I cannot say for sure nothingbutdarts...