2002 – 2006 Dodge Ram 9007 LED Headlight Kit Install Writeup – DIY How To

For a long time it was known that the only way to do a plug and play lighting upgrade on the 2002 – 2006 Dodge Ram was to either use higher power halogen bulbs, or an HID conversion kit with a bunch of extra parts like resistors, a relay harness and capacitors. Because of this every time I heard about someone working on one I would get scared and not even want to help with it – it is an AWFUL install! Now with the invention of LED conversion kit bulbs and CANBUS modules for them, we decided to give this difficult vehicle a shot to see if we could install LED conversion kit bulbs easier in a 2003 Dodge Ram with 9007 headlight bulbs. Doing this install (once wired properly) proved to be a truly plug and play experience with no flickering and no “LAMP OUT” warning on the dash!

Using a GTR Lighting LED Conversion Kit and the matching CANBUS module we were able to get LED headlights installed pretty easily!

Using a GTR Lighting LED Conversion Kit and the matching CANBUS module we were able to get LED headlights installed pretty easily!

This particular truck was dated September of 2003 and used 9007 bulbs.

The first step was to get the new LED bulbs to actually fit inside the housing! Because the base of the bulb that holds the fan and heat sink is so much larger than the original bulb we had to use a bench grinder and shave about .25 inches off of the gray plastic retaining ring to allow everything to seat correctly. This took a few minutes and just took a little off at a time, tested it and kept doing that until it all fit together nicely.

The LED bulb comes apart. There's the bulb adapter that comes off and is secured to the housing by the gray plastic retaining ring, and the entire bulb assembly. We had to modify the plastic retainer before the new LED bulb would fit in place like the original.

The LED bulb comes apart. There’s the bulb adapter that comes off and is secured to the housing by the gray plastic retaining ring, and the entire bulb assembly. We had to modify the plastic retainer before the new LED bulb would fit in place like the original.

The 9007 LED Headlight Conversion kit bulbs are much larger on the back side than the original 9007 halogen bulbs.

The 9007 LED Headlight Conversion kit bulbs are much larger on the back side than the original 9007 halogen bulbs.

After getting the bulbs to seat properly in the housing we took the GTR Lighting CANBUS module for 9007 out of the packaging and hooked it up straight away and the capacitor inside the module popped! The module actually exploded!! I’m not kidding – a little pop, some wet stuff came out and the little thing stunk to high heaven and smoked for a second. This wasn’t all too surprising though since when you hook a capacitor up backwards it will explode. That’s exactly what happened – the capacitor inside was wired wrong for this truck and exploded. So, after that excitement we took a new set of 9007 CANBUS modules and re-wired them so that everything looked like this:

 

This is how the bulb was installed: The CANBUS module is between the bulb and the vehicle harness.

This is how the bulb was installed: The CANBUS module is between the bulb and the vehicle harness.

This is the connector going from the 9007 LED Headlight into the 9007 CANBUS module. We had to change these wires around to make them work.

This is the connector going from the 9007 LED Headlight into the 9007 CANBUS module. These wires were correct from GTR Lighting.

This is the connector back side of the 9007 LED CANBUS module input. We had to change these wires around to make them work.

This is the connector back side of the 9007 LED CANBUS module input. We had to change these wires around to make them work.

This is the connector back side of the 9007 LED CANBUS module output that plugs into the factory wiring. We had to change these wires around to make them work.

This is the connector back side of the 9007 LED CANBUS module output that plugs into the factory wiring. We had to change these wires around to make them work.

Just for reference sake, here's what the back side of the original factory connector looked like.

Just for reference sake, here’s what the back side of the original factory connector looked like.

 

So, all in all we got it to work after thinking about it and how to re-wire the CANBUS modules, and they’re definitely brighter than the stock headlights. Because they are LED they should be more reliable also.

Here you can see the new GTR Lighting LED bulb in the headlight housing.

Here you can see the new GTR Lighting LED bulb in the headlight housing.

Here's a final install shot showing the new 9007 LED Headlights from GTR Lighting in high beam mode.

Here’s a final install shot showing the new 9007 LED Headlights from GTR Lighting in high beam mode.

Jeep LED Fog Light Upgrades: Review of the Four Best Options.

If you are looking to upgrade your Jeep Wrangler JK fog lights, you’ve probably thought about making the switch to LED. Here is a video that talks about four of the most popular LED fog light options for the Jeep JK. This video will walk you through all the specs of the different LED fog lights, show you the pros and cons, and walk you through the installation of each light in a Jeep Wrangler JK front bumper. The video does go in-depth on each LED light, so we’ve broken the video down for you. After watching this video you’ll be ready to make the choice of what LED fog light is best for your Jeep JK.

This video reviews the Truck-Lite 80275, the JW Speaker 6045, the JW Speaker 6145, and the Vision X 2″ 10w Solstice Solo.

 

The first two LED Fog Lights reviewed for the Jeep JK are the Truck-Lite 80275, and the JW Speaker 6045. Both of these LED Lights are PAR36, 4.5″ lights, and as you can see from the video, both of these lights use extra brackets to mount them from behind the JK bumper. At 8:34 you can watch the steps to install both of these lights.

PAR36 LED fog light mounting bracket

 

Here’s a quick look at the specifications of the Truck-Lite 80275 and the beam pattern it gives off. The 80275 is a great cost saving option for new LED fog lights especially if you already have the Truck-lite LED headlights.

truck lite fog lighttruck lite fog light beam pattern

 

Here’s a quick look at the specifications of the JW Speaker 6045 and the huge beam pattern it gives off.

JW Speaker 6045 LED Fog lightjw speaker 6045 beam pattern

 

 

These next two options are great because they have built in brackets for an easy behind the bumper installation. These are the JW Speaker 6145, and the Vision X 2″ 10w Solstice Solo. At 18:54 you can watch the mounting of these two lights in a Jeep bumper.

Jeep LED Fog Lights with built in mounting

 

Here’s a look at the specifications of the JW Speaker 6145. The design is a little smaller than the 6045 predecessor, but that allows the light to fit just as well as the original stock fog light housing. Here you’ll also see the impressive beam pattern that has a great color.

JW Speaker 6145 LED Fog Lightjw speaker 6145 beam pattern

 

 

And the last LED fog light reviewed is the Vision X 2″ 10w Solstice Solo. Here you’ll see the specs and the beam pattern. This fog light was designed for off-road use and gives off a long beam of direct light.

10W Vision X Solstice Solo LED Fog Light10W Vision X Solstice Solo LED Fog Light beam pattern

 

If you want to look at more pictures and pricing of any of these fog light options, check out the Jeep Wrangler section at Headlight Revolution here.

Here is the full video:

 

How to stop JK Jeep Wrangler Flickering LED Headlights

This is a harness made by Headlight Revolution that was the first product ever to solve the flickering problems when installing LED headlights in the JK Jeep Wrangler.

This is a harness made by Headlight Revolution that was the first product ever to solve the flickering problems when installing LED headlights in the JK Jeep Wrangler.

One of the most popular things happening in the Jeep market right now (other than Vision X LED Off Road light bars) are LED headlights. Several companies make a light that will fit the opening of the Jeep that uses a 7″ round headlight housing, but nobody makes one specifically for the Jeep. This is a problem because the JK Jeep Wrangler (2007+ Models) use a special CANBUS functionality built into the lighting circuit. This is a good thing because it is a more intelligent design to control the lighting but it makes modifying the headlights a difficulty. This is how to fix the flickering problems you will encounter when trying to install LED headlights into your JK.

This is the only thing you need in order to install flicker-free 8700 LED headlights into your 2007-2014 Jeep JK.

This is the only thing you need in order to install flicker-free 8700 LED headlights into your 2007-2014 Jeep JK.

Without doing any modifications to the wiring, if you install LED headlights, like the JW Speaker 8700 Evolution, or the Truck-Lite 27250C the lights will flicker, flash randomly or strobe. This can cause headaches for the owner of the product because it will seem like the product is defective.

Jeep JK Wrangler with LED Headlights, no flashing

With the anti-flicker harness from TLG-Auto you can install any LED headlights in your Jeep Wrangler without any flashing or strobing problems!

If your LED headlights installed in your JK Jeep flicker or strobe, the lights are not broken – IT’S A PROBLEM WITH YOUR JEEP! Don’t send the lights back. Instead just buy the harness. You need THIS HARNESS to work with JW Speaker 8700 or you need THIS HARNESS to work with Truck-Lite 27270C. The Jeep Wrangler JK Anti-Flicker harness for JW Speaker LED headlights is made by Headlight Revolution and will solve your LED headlight strobe problems. This is a plug and play harness and requires no modifications, and you don’t have to hook it up to the battery! Simply plug it into the LED headlight and plug the other side into the Jeep – THAT’S IT!

Jeep Wrangler JK no flashing problems

With the anti-flicker harness from Headlight Revolution you can install any LED headlights in your Jeep Wrangler without any flashing or strobing problems!

HID Relay Harnesses Explained

xenon wiring harness

A typical relay power harness for HID Conversion Systems.

The primary function of an automotive headlight wire harness is to provide power directly from the vehicle’s battery to the lighting system. This allows the bulb, or HID ballast, to operate independently of the vehicle’s original wiring system and can provide a power source that is more consistent.

A lighting relay harness is most commonly used in aftermarket HID conversion kits to bypass the factory wiring in order to get around complicated electronic control systems or to allow a higher rate of current to be delivered to the bulbs. A Relay Wiring Harness utilizes a 30amp fuse protected power wire that directly connects to your positive terminal on the battery.  An Automotive Relay is used to pull signal from a source (Headlight connector) that triggers power to be drawn from the battery.  There are two sets of cables meant to provide power to an HID ballast.  There are also two separate ground wire terminals that need to be connected to the chassis to complete the electrical circuit.

relay harnesses explained

The different components of the Accessory Wiring Harness.

As previously stated, this product is most commonly found used in aftermarket xenon retrofits but can also be beneficial when trying to get the most light output from aftermarket or OEM halogen/incandescent light bulbs. Any lighting system can benefit from increased current capacity in the wiring. GTR Lighting offers a wide array of Plug and Play Relay Wire harnesses for H7, H8, H9, H10, H11, H13, 9004, 9005, 9006, 9007 and more. Visit GTRLighting.com to learn more about the different wiring products available.

What does a Wiring Harness fix?

An Relay Wire Harness is capable of fixing a variety of power related HID lighting issues i.e. intermittent on/off, flickering, delayed start, HID low light output, and uneven brightness.

Problem: Delayed Start
An HID Ballast requires more power to ignite on start-up than during normal usage.  This initial power surge can sometimes be problematic for vehicles with weaker electrical systems that cannot provide the power needed.  The vehicles stock headlight connectors are not capable of providing 7-8 amps per headlight and as a result, only one HID turns on when the switch is turned on.  After about 20 seconds when the ballasts power consumption drops to 3.2 amps, you can quickly turn the lights off then back on and voila, both HID lights turn on.  This scenario happens all the time and is the direct result of insufficient power.

Solution:

An HID wiring harness with power supplied directly from the battery would eliminate this issue as it would be able to consume up to 30 amps through the batteries positive terminal to ignite both ballasts.

Problem: Flickering
An HID Ballast that is not getting sufficient power from a stock headlight connector will cycle on and off as it tries to ignite and power on.  This can also be a result of an inefficient ballast that is not able to convert the available power to properly ignite an HID system. I always recommend high quality HID components like the 35w CANBUS Pro ballast from GTR Lighting.

Solution: 
An HID wiring harness will provide the power necessary to ignite even an inefficient ballast for flicker free HID lighting.

Problem: Dim/Dark Light Output:
When a ballast is under-performing, light output can appear more blue and dimmer than it should be.  This is a result of the ballast not converting enough power to ignite the bulb at its optimal range.   A bulb that is 4300K connected to a ballast with a weak power source, can look like an 8000K blue color with substantially lower light output.

Solution:
An HID Wiring harness will be able to provide more power to the ballast allowing the system to operate at 100%.  This however is not a guaranteed solution as a poor quality ballast which will not output sufficient power no matter how much is being inputted.

Problem: Uneven Brightness
My passenger side is brighter than my driver side!  Power in not always delivered in equal amounts to each headlight, and depending on your vehicles wiring configuration, can have a negative impact on lighting performance when installing HIDs.  If one headlight has less resistance to the power source i.e. length of wiring, fuse panels bridging connections etc, it will receive power first leaving less for the second headlight to consume.  In this scenario, one headlight could end up being brighter than the other, or powering up to full brightness faster than the other.

Solution: An HID wiring relay harness will provide equal amounts of power to each HID Ballast allowing for even and consistent brightness between both headlights.

To Buy or Not to Buy?
An HID wiring harness for some vehicles is a safety and assurance item to prevent future problems, and for other vehicles is a necessary requirement to a successful HID installation.  My general recommendation is to always use a harness where possible to help extend the life of your HID system, avoid unnecessary headaches, or to boost the output of your halogen light bulbs.  Not only are you providing your HID ballasts with adequate power, you are protecting both your vehicle and HID system with the inline fuse that separates the systems.