2nd Gen Non-Engine/Transmission Brite Box and headlight Issues

[surfbeetle]

I got the upgraded 2nd gen headlights for my '95 about a year and half ago and also got the brite box, both from Geno's. Over the past two weeks we were on a road, did 4881 miles pulling the fifth wheel. Along the way, we did have to replace the headlight switch (there's a 911 thread on that) but everything worked great after the switch was replaced.

The last night of our trip, we drove from Sedona Arizona back to San Diego Ca with the high beams on for quite a bit of time. The outside times were around 100 degrees. About two hours from home, the right side highbeams failed to come on. The low beams on both sides work fine, the high beams on the left side come on and then both bulbs on the right side go out when set to high beams. When I'm flipping the lever from low to high beams, all lights come on when the lever is halfway and then the right side goes out once it's set to high. The Brite box is mounted by the passenger side battery. This leads me to think that the brite box is having some issues but I don't know where to start troubleshooting. Does anyone have any ideas where I should start?

 

[seafish]

While a nice idea, IIRC some of the older Briteboxes were prone to failure due to overheating of the electronics inside and the subsequent melting of electrical contacts. If at all possible (I do not remember how easily they connect or disconnect to the vehicle witting harness) I would suggest simply removing the Britebox from the equation to see if your problems go away.

It was for this very reason that myself and a few others were motivated to achieve the same goal as the Britebox but by modifying the oem MFS instead of adding a Britebox. I don;t know if the mod can be done on a second gen truck, but here are a couple links for the easy to do mod on 3rd gen trucks--

https://www.turbodieselregister.com/threads/148135-Poor-mans-bright-box

https://www.turbodieselregister.com/threads/94631-BOMBed-Multifunction-(high-beam)-Switch

 

[surfbeetle]

Thanks Seafish, since my truck is an early 2nd gen originally with just one bulb on each side, the brite box is what allowed me to plug and play and switch over to the newer sport headlights. Without the brite box, I am not able to just plug in and test the headlights. I was not aware of the heat issues in the brite boxes, I'm assuming that this must be what has occurred with mine since it was very hot when we were driving, thank you for this information.

 

[seafish]

A little more detail--


https://www.turbodieselregister.com/threads/192679-Brite-Box-dead-again-disposable

Perahps you could eventually build your own relay set-up to run your sport headlights…it could definitely use higher quality parts.

 

[Bob4x4]

With the assistance of a good parts man I sourced all oem parts :sockets,relays and terminals to build plug in harnesses for 12 valves to use the sport lights.Using better components and wire gauge than any of the aftermarket kits.As far as I know all of them are still functioning fine.The aftermarket kits all used less tha oem quality.

 

[crabman]

I have had the same problem with the brite box, returned and got a new one.
I have a brite box on my 06. The 98 has sport headlights w/wire kit made by fellow member firefighter. Hands down, 98's lights are much brighter than the 06. The difference is the wires, 12 gauge versus 18 gauge(or 20?) & direct connection to battery=no voltage drop.

 

[BarryG]

I had a problem with a brite box as well about year or so after I added the sport headlights and the brite box. My low beams quite working then about a month later my high beams wouldn't shut off even with the switch in the off position. Thought it was the MFS switch so I swapped a good one in and still same problem. I had totally forgotten all about the brite box but once I remembered it and pulled it everything worked like it should except for the not being able to run high and low beams together any more been working fine ever since. I opted not put another one back in since the first one only lasted about year.

 

[seafish]

IIRC, Daniel Stern at http://danielsternlighting.com/products/products.html

can make custom light harnesses from quality parts, sold either as a kit or as completely built.

Some of you guys may want to email him at the link above.

That being said, if you have not browsed his site yet (all about vehicular forward lighting), it is WELL worth doing!!!

 

[6speed]

I had issues with mine. I contacted the maker. I can't remember the name but Genos gave the name to me. Called them with the complaint, gave me some trouble shooting items. Determined it was the box. Sent it in, repaired it, got it back and no problems since.

 

[BarryG]

Daniel Stern does make a very quality harness. I opted to have him build it for me instead of just sending me the parts. I was very impressed with his harness. And as Seafish mentioned his website is quite informative.

 

[surfbeetle]

Thanks for the info. I think I'll call Geno's and see what can be done.

 

[surfbeetle]

I was deleting old email and found this message. Here's the update, the fuse had blown and upon replacement the lights work correctly. If I have the high beam lights on for too long, the fuse will blow again. In June of 2016, I pulled the trigger on a new 2016 Cummins Ram 2500 Tradesman 4x4 Crewcab Longbed. So for the most part, the 95 just sits and gets driven a couple times per month and as a result, I haven't addressed the fuse blowing issue. Once my daughter starts driving the 95, I'll be more motivated to make sure it works properly for her. Thanks again for everyone's assistance with this.