Rewiring the AUX switches for more power? EDIT: Solved, how-to wire in relay and lights to AUX

[l88m22vette]

This question is based on a Lighting thread of mine https://www.bronco6g.com/forum/thre...-use-aux-6-would-swapping-to-leds-help.68418/ where the solution was to use the harness the lights came with, but cut off the harness switch and use the AUX in place of that one. It works, but I really want something that's more OEM+.

One of the ongoing discussions is about the AUX wiring, and how its not really as robust as it could be. Its been a few years since I had to do any tracing, so I'm rusty, but I've been wondering if it would be possible to just rewire the whole OEM setup? Would it be possible to swap wires and bump up the fuse rating, such as swapping AUX 6 to 14ga wiring with a 20-30 amp fuse? Could the stock distribution block and connecting harnesses handle that, or would it screw everything up?

And yes, I know the real solution is to get more modern lights for lower amps, but I love the 500s. My only thought was an H3 LED, but apparently those are all useless, and the Hella H3 upgrade is a fog bulb and these are driving lights.

EDIT: see solution below

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[Boreal]

Use a relay.

Rewiring the Aux lines doesn’t adjust the ampacity that can necessarily flow through its fusing/relays/switch assemblies.

That’s like adding a 3” diameter hose to your kitchen faucet and expecting 700GPM, when in reality the system is only able to output 100GPM. No matter what you change the wiring to, it doesn’t help the base amperage available.

 

[swooshdave]

And yes, I know the real solution is to get more modern lights for lower amps, but I love the 500s. My only thought was an H3 LED, but apparently those are all useless, and the Hella H3 upgrade is a fog bulb and these are driving lights.

That is the actual solution. Get modern lights.

Or as someone said, get relays.

 

[l88m22vette]

I'd like a set of the KC LEDs or Daylighters, I wish they weren't almost $500

 

[Bruno]

Is there a HOW-TO on using Aux Switches with relays to add lights ?

 

[Theherofails]

Is there a HOW-TO on using Aux Switches with relays to add lights ?

Very simple.

Cut the toggle switch off the harness, hook the (almost always) white wire to your aux wire, ground the black wire and tape off the red wire. Hook the other side of the harness to your lights and the battery terminal cables to the battery. Install is done.

 

[330SMG]

Is there a HOW-TO on using Aux Switches with relays to add lights ?

There are but it is simple.
Wire your accessory to the output side of the relay 87
Wire the battery to the input side 30
Wire the aux switch the trigger input 86
Wire the other side of the input to ground. 85
They sell 200 250 500 etc size relays
Plenty of Youtube videos especially with winches.

 

[l88m22vette]

That approach worked perfectly Hella 500s with Deutsch 2-pin connectors, soldiered and heat-sealed with a mesh cover. 4x4TruckLEDs Deutsch splitter light harness wired into the Hella relay kit, which was butt-spliced and heat-sealed to AUX6. Two negative wires (one from light harness, the other for the relay) and one positive wire.

 

[FatRat250]

This is what I used, it’s like a spod makes for the Jeep. Rough Country MLC-6 light controller. I ran my aux switches to the inputs for this, and then you can run your more powerful relays.

I’m generally not a fan of rough country products, but this one is actually good quality and works perfectLy.

https://www.roughcountry.com/mlc6-m...2bpS8Vg8hg1NEjaatHJu3kanqXfkdBw4aAr4zEALw_wcB

 

[l88m22vette]

Thanks! I like that a lot, wow, I might have to grab one

 

[GeorgeFromDallas]

This is what I used, it’s like a spod makes for the Jeep. Rough Country MLC-6 light controller. I ran my aux switches to the inputs for this, and then you can run your more powerful relays.

I’m generally not a fan of rough country products, but this one is actually good quality and works perfectLy.

https://www.roughcountry.com/mlc6-multiple-light-controller-70957.html?utm_source=google&utm_medium=cpcs&utm_campaign=18022125814|&utm_content=&utm_term=||m||fit_first_70957-a&gclid=Cj0KCQjwz6ShBhCMARIsAH9A0qWK8iBwn5_rOowAcf9VdGe2bpS8Vg8hg1NEjaatHJu3kanqXfkdBw4aAr4zEALw_wcB

Did your hood close with it Installed?

There was another thread where the “Bronco Kit” had major hood clearance issues.

Maybe RC has already redesigned it.

I’m wanting to try one, too.

 

[FatRat250]

Did your hood close with it Installed?

There was another thread where the “Bronco Kit” had major hood clearance issues.

Maybe RC has already redesigned it.

I’m wanting to try one, too.

I bought mine a year ago, so not sure if it’s a redesigned one or not, and clearance is tight, but no issues so far. You can see where is rubs the insulation / hood liner.

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