Custom built Headlight Wiring harness for 1993 - 2009 Ford Ranger


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Forum Member

Joined
Apr 17, 2025
Messages
161
Points
101
City
N/A
State - Country
TN - USA
Vehicle Year
99
Vehicle
Ford Ranger
Drive
2WD
Engine
3.0L
Transmission
Automatic
Total Lift
2”
Tire Size
15”
I've been doing lots of research on upgraded wiring harnesses, that would allow for a higher amperage drawing bulb or even using both high and low filaments at the same time. The default wiring for the Ranger comes off the multi-function switch. According to the tech libraries it loses about 10% of the voltage, which is equivalent to 1.2v. The tech Libraries say this causes a 33% decrease in light output. So, a lot of guys will run wiring straight from the battery through a relay to the headlights. Putco makes a wiring harness and so do several other brands, but they are all 100 watts and use 16-gauge wire. Not to mention they don't appear to use standard relays. I don't want to risk overloading these harnesses, and reviews say the connectors are low-quality plastic not ceramic. I'm considering building my own harness with the highest quality connectors, 40-amp relays, 14-gauge wire, and 16-gauge signal wire. I'm now wondering if anyone else out there is interested in their own custom harness. I'd be more than willing to build several more, I could build it to whatever specifications you want. IS anyone else interested in a custom-built wiring harness, or has anyone found a good pre built harness?
 
If you're going to run both high and low simultaneously, it may be wise to upsize the ground wire from lamps to frame, also.
 

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