1999 Explorer Sport - OFF ROAD LIGHTS

Show ya one drawing/set of plans I made already.
I'll work on your requests some tomorrow morning.

Hella relays are great quality and are rated @ 40 amp.
10 gauge wire is recommended even though the factory
gets away with that small 18-20 gauge stuff.

The wiring colors are from a 1996 and should be the same for 1999
like on muh 2001 Ranger XLT.
The "blue" fog lights are the additional aftermarket aux.
lights proposed for above the bumper mounting.





Running all lights (high-low-fog-aux lights)
at the same time will draw roughly 60 amps.

Each relay has pins 30 - 87a - 87 - 85 - 86
Usually 40 amp Hella relays are wired:
30 - Connect to fused 40 amp 12 volt source
87 Normally open
87a Normally closed
85 Coil trigger
86 Coil trigger


DOT law states foglights must go off when
high beams are on.

This is my "Sure to get a big fat ticket" light setup.
This also returns everything to "stock" factory with the
toggle switch off so if someone else drives your rig
you can hide the toggle.

Use at your own risk. not responsible for tickets/fines.

Relay 1:
Right headlamp high beam (passenger side) wire cut Light Green/Black. Headlamp side of this wire connect to pin 30.
Connect harness side Light Green/Black to pin 87a . This will make it "normally closed" and
operate as if you never cut the wire when the in cab toggle switch is off. Pin 87 to 12 volt 10 ga. 20 amp fused wire from battery.
Pin 85 to ground. Pin 86 connects to a wire from Relay 3 pin 87 described later.
Relay 2
Right headlamp low beam (passenger side) wire cut Dark Blue/ Light Green. Headlamp side of this wire connect to pin 30.
Connect harness side Dark Blue/Light Green to pin 87a. Pin 87 to 12 volt 10 ga. 20 amp fused battery wire. Pin 85 to ground. Pin 86 to Relay 3 pin 87.
Relay 3
Connect 20 amp fused 10 ga wire to pin 30, usually red, you can use can use a different color just knowing it is 12 volt fused and within 8 inches of battery.
Pin 87 goes to fog lights red wires, this wire can be made into a "Y" split at the foglights.
The female terminal here will need an extra smaller 16-22 ga wire to send to relays 1, 2, 4 and 5 coil trigger pin 86.
Pin 85 to ground. Pin 86 to "supply" side of toggle switch located inside cab.
Pin 87a not used.
Relay 4
Left headlamp low beam (driver's side) cut White/Light Green. Connect headlamp side to pin 30.
Connect harness side White/Light Green to pin 87a. Pin 85 to ground. Pin 86 to wire from pin 87
Relay 3.
Pin 87 to 12 volt 10 ga. 20 amp fused battery wire.
Relay 5
Left headlamp high beam (driver's side) cut Light Green/Black. Headlamp side of this wire connect to pin 30.
Connect harness side Light green/Black to pin 87a. Pin 85 to ground. Pin 86 to wire from pin 87 Relay 3. Pin 87 to 12 volt 10 ga. 20 amp fused battery wire.

This setup will not allow for aux. light only use with the in cab toggle switch off.
I have a different setup in mind for that and will work on it tomorrow sometime.

 

damn joe....lol

 

If that don't scare the wire strippers and
crimpers outta ya hands nothing will.

 

joe on a dual filament bulb do both filaments turn on when you flip on the highs? or is it one at a time?

 

Like a 9007 bulb, One at a time.

 

HOW-TO: Fog Light Mod - Ford Explorer Forum - Forums for Ford Explorer Enthusiasts

I haven't done this ^ fog light mod, but it sounds easy,
jumper across the second factory fog light relay terminals (pins) 2 - 3.

If my previous design had an extra toggle on pin 87 Relay #3
or the ability to stop the triggers of Relays #1 #2 #4 #5, the
aux. fog lights could run by themselves using the first toggle switch.

Every Hella fog light harness we built for Choo Choo Customs
had to have the DOT high beam interruption.

When I started there in 1995 the production numbers were in the 22,000 range.

When they closed in August 2000 the production numbers
were in the 83,000 range. Somewhere around 60,000 vehicles in 5 years,
or about 41 vehicles average per day.
On just the pickup truck line I could wire 10-15 trucks per day.
One day I wired 17 fog light harnesses.

 

with what Joe posted above your going to need a 20amp switch.

 

So your extra lights shut off with the highbeams? That doesn't make much sense to me. I wired all my lights to come on with my brights lol.

 

good information.

Alright, I couldn't find a headlight relay under the hood. There is another box of relays under the dash. I keep reading that if it doesn't have "autolamps" then it doesn't have a relay... I don't know, I can pull the relays and see if they turn out the lights though. Trying to find a good starting point.

Edit:

Ok I just pulled a few relays one at a time, Found one that shut off Parking + Fog lights, but not high or low beams.

 

Bend the fog light relay terminal as shown, replace relay, now the fogs stay on even with the high beams on.
DOT (Department Of Transportation) requires fog lamps go off when high beams are on, not responsible if ya get a ticket,
or worse maybe road rage from another driver.