2nd Gen Non-Engine/Transmission Sport/Quad Headlight Bulb Question

[Matt42]

I got my 1996 back from the paint shop two days ago and I'm putting parts back on. It's a general color change, and the result is what I'd call a good 15 foot paint job. I retained the OEM Emerald below the belt line, but changed everything above to the 1994 Ram Van Arctic Gray. It needs some touch-up and the shop owner knows it. I didn't pay for a car show paint job, and I didn't get one. It is not flashy and the shop owner thinks I am nuts.

I'm making other changes, and one of them is a Sport headlight conversion. I received a set of headlight assemblies today, minus the bulbs. I was expecting that, thinking it would be simple to figure out what bulbs went into which parts. Wrong-O.

So on the models with the sport headlights, is the high beam a 9004? Is the high/low beam a 9007? Or do both use 9007 bulbs? Will the bulb spaces accept either bulb model number?

I'm not wiring a brite-box conversion. Instead, I am going to use an old-school floor-button switch with relays to activate the high beams. They will be on their own fused 14 or 16 gauge circuit, completely independent of the stalk-mounted light switch, and they will have a separate blue upper beam pilot light.

 

[Matt42]

And then I found this thread, from two years ago. https://www.turbodieselregister.com/threads/sport-conversion-wiring.273389/
As is usually the case, Iron Duke II is two years ahead of me.

 

[petersonj]

The 9007 bulbs are a dual filament bulb (55 watt and 65 watt). They are the outer bulbs.
The 9004 bulbs are also a dual filament bulb (45 watt and 65 watt). They are the inner bulbs. OEM operation is as follow:

Low beam selected: Two outer bulbs (9007) on low beam filament (no high beam operating)
High beam selected: All four bulbs (9007 and 9004) on high beam filament (no low beams operating)

The 9004 (inner bulbs) low beam filament is not used at any time.

A couple of tips: Don't be tempted to use the 9004 (inner bulb) low beam circuit. The reflector is not designed for the low beam and just scatters light - no good for you and annoying to oncoming drivers

Use relays. They carry the heavy part of the electrical load (directly from the battery to the lights) which significantly reduces voltage drop and puts much more light on the road. Also, the relay control wiring draws only about 200 milliamps - much better for long wiring runs and switches.

For the conversion on older second generation trucks you will need to do some metal cutting. Geno's Garage will help you here.

https://www.genosgarage.com/downloads/TechPDF/TDR77_HeadlightConversion.pdf

- John

 

[Matt42]

Thanks, John. I did the metal cutting before the truck got painted.

 

[petersonj]

I did the metal cutting before the truck got painted.

Good Thinkin'!

- John