SR/SR5 OEM LED headlight conversion harnesses

This is the kind of Cinderella story I want to hear. Super excited to get my hands on this holy grail harness!

 

While I am glad you got everything working, I am a little stumped as to what the issue might have been. Was it on the headlight side you did that? The 3-way going to the 6-port connector?

 

Yes, it was on the head light side the 3-way that connects to the 6-port connector. I removed the plastic tooth on the 3-way, rotated the 3-way and it worked. Two of the wires were routed incorrectly on that side?

 

Received the harness. But have no turn signals. What do I do? I dont see how you can flip the 3 connector upside down.

 

Okay. Thank you! I will try that.

 

@GreenTea I was chatting with @Degore21 and realized I messed up on the wiring on these. (also @fujiiheavy @p@ul @SkinnyLegend @jasonf2021 @TheoremMelodica @Deacon85 @wai-129 this is relevant to you as well). I have two wires crossed. It is an easy fix, and I have sent the first round of PM's. I will post the instructions on correcting it here if you'd like to DIY, and will include further instructions to send them back to me to be corrected (on my dime of course). Really sorry about this. It is an easy fix, so at least that is good.

 

Ok, here are the instructions for repairing batch 2. I used a small pick, but a tiny flat screwdriver or even some pointy tweezers will work. Step one, identify the plug. The passengers side has a blue with white stripe in the center, and the drivers side is pink. The other wires on each side of it are what we are interested in swapping. The center wire doesn’t move, just the wires on each end.

We want to pull those “two” wires out and swap them. So start by removing the TPA (the white plastic thing inside the plug housing)

It just gets pulled straight out. It might come loose, and feel like it is seated in a new position, just keep pulling or prying it until it is all the way out.

OK, now with that out of the way, look down into the housing. Where that white plastic was, you will see three grey plastic tabs seats in the three terminals. Remember, we only care about the ones on the side. We are going to pry that grey tab out of the terminal. It doesn’t take a lot of force, and doesn’t need to go real far.


Once that is popped out of the terminal, you can pull the wire and terminal out of the housing

go ahead and do both sides, swapping the RED/BLACK and YELLOW/BLACK/BLACK. The terminals should just push in and click. Make sure the grey tabs seated in the terminals okay and replace the white plastic piece. The plug should now look like this:

That’s it. Now when you plug it in to the truck, that RED/BLACK wire should line up with either TAN or LIGHT BLUE. The YELLOW/BLACK/BLACK wire should line up with the WHITE wire with a BLACK STRIPE.

Once again, sorry about this. I messed up on my bench test harness, which just snow balled into this. I will still be sending PMs to those who want to just ship it back and have me do it, so if it seems like something you don’t want to try, I get it.

 

I believe I sent everyone affected by the 2nd batch error at least two PMs. Let me know if you didn't get them, and once again, sorry about this. I once told @daveeasa that I basically recreate this stuff from scratch each time I do one (my mind is a little scattershot sometimes), so I guess this was bound to happen. But the good news is going forward (in a week or so at least) I will have an actual headlight to test with! So next time I screw up (lets be honest, I know I'll do something stupid again) I will at least catch it before I mail everything out

 

I had my first DIR screwup this week too. And then there was the previous mistake with the MX-150 terminals I did backwards which I still have one left to fix.

 

I guess this is to be expected with handmade harnesses. I still hate that it happened, but everyone has been pretty cool about it and understanding.

 

Ok, want to drop an update for everyone patiently waiting on batch 3 (and this is also relevant to batch 1 and 2 as well). It has come to my attention that some of the HDRL controllers do not like these headlights. I am not sure at this time what determines if they do or do not, but it is about 40% of them. I just tested 27 total controllers, and out of that, 11 did not function correctly. They would not flash correctly, seeming to almost skip every other flash. The ones that did work seemed to work okay. I hooked all of them up, and if they failed, it seemed to do so within the first couple of flashes. If it didn't fail right way, I ran it for 5 minutes. Then it went into the "good" pile. Then I ran the whole "good" batch again, turning the blinker on and off, with and without DRL. THEN, I ran each one a third time for another 3 minutes. I have been doing this for over 5 hours now, but I need to know that these will work. Ultimately, I am just a guy who spends his time in his laundry room making things do things that those things aren't designed to do. But I still want to make sure that people are getting a good product. I will be discussing the issue with VLED, but I do not anticipate them knowing the cause either. I also do not expect them to warranty the ones that are "bad" precisely because this is not the controllers intended use.

So, what does all of this mean? I am not positive yet. I know the first few of these are still working fine. So it seems to be a pretty definitive "yes, it works" or "no, it doesn't work" right away. IF you are experiencing issues, I am going to have some of these tested and ready to go for replacements. As to the "failure" rate (I hate calling it that, because the controllers are still fine for their intended purpose. Calling it a failure makes it sound like it was VLED's issue, which it is not), IF there is a batch 4, I will have to incorporate that into the cost unfortunately. Which means adding $30 to the set of them. I really hate to do it, but unless someone has a creative idea for the controllers I can't use, I am going to be sitting on a bunch of them, and that adds up. I don't make a whole lot off of these, which is fine. But at the same time, with an unusable rate that high, I would be basically selling these for a few dollars above cost.

So for now, I can cover what has been promised with batch 3 if you are still interested at the promised price of $150 ( @LongX @Integerdy @ArmyTaco21 @Antics @zacharyrgonzales ), but going forward, I will still be giving it some thought....

 

I am still very interested in a harness for batch 3. Really happy to see you going above and beyond to test these things, although I feel bad that it's at a cost. Hope you find a solution.

 

Thanks! I am still confident in the design, it is frustrating not knowing why they are doing this though. But the ones that have had issues have had it right away. The ones that didn't have the issue haven't had any issues. I am willing to cover the controllers for a year as well. I don't plan on leaving anyone out to dry on this. The harness part itself I will cover for life as there is not much that can go wrong once its assembled correctly.

And a note on the testing. I have an actual headlight now, which has made a huge difference (this issue didn't show up on my indicator light test station). Unfortunately, having seen the OEM LED headlight in person up-close, I REALLY WANT A PAIR NOW! These are great looking headlights! I can't say much for how they illuminate the road or anything as I had mine aimed into the cab (its freaking bright that way, I know that), but man, they look good.

 

Just send to @no vtec 4me and he can double-chrome yours so that it's all gold and blingy.

And, yeah, you need them. F halogens.

 

I don’t know that even I could go chrome on these… that black is just sexy!

 

I’m still interested for sure. I’m also willing to pay the extra 30$ to offset this issue. I really appreciate the work and thoughtfulness of trying to provide a quality product even if it is at the hobby level rather than a business.

 

@LongX @Integerdy @ArmyTaco21 @Antics @zacharyrgonzales I was going to send this as a PM to each of you, so please just PM your response if you want. I was typing it and thought it might have some value as a public post though....

As you know by now, there were some issues that came up regarding the VLED HDRL controllers that I use in these harnesses. While I do believe I have isolated the "bad" controllers, I still hate the fact that I have even had to do that. If I just spent $1400+ on some sexy headlights, I would just want them to work. That is what I would hope for, and what I was trying to deliver to people. I failed on that. Everybody has been really cool about it, and I will still do everything within my power to make sure that they can continue to enjoy those sweet LED generated lumens, I just have worries continuing to to offer these harnesses. This is where you come in. You are the next in line for batch 3. I will still honor that and can ship these Monday if you decide you want to maintain that spot in batch 3. I have controllers sitting here, tested, and feel pretty secure in them working after the testing I put them through, but I am still not 100% on that. So here is where the other side of the offer comes in: I can swap your spot in batch 3 for a spot in batch 1 of SR to LED harness V2.0. These still function the same, the difference being the parts I am using to make them, and a slightly more complicated install. The install is still plug and play, and can be accomplished almost tool-less (you might need a wrench and screwdriver to mount two relays, and maybe crimp one wire depending on your particular power tray set up if you have one). These will use a single wire ran from a hot source (like the battery, or a power tray), or it can be ran using a fuse tap in the under hood fuse box. The amperage draw in really low, so if you have raptor lights or something already there, you would be fine splicing the wire into it as well (it's like 0.2A tops) But that wire is new to this version, so it makes the install go from like 10 minutes to maybe 20? So not terribly hard. There is a slight delay in the DRL coming on (not off, or from DRL to turn signal, just back on or from turn to DRL), but that is also present using the VLED HDRL controllers, it just might be slightly longer here. That delay is programmed analog by hand, so it will vary, but I know I can shorten it up (the delay in this video was deliberately long. It only needs to be longer that the time the turn signal is illuminated, so hopefully 1 second as opposed to the 2+ in the video). Anyway, without knowing the issue as to why some HDRL controllers work and some do not, and there by not being able to control for it, I think this is the best route going forward. I will be ordering parts for these this weekend, and should have them by next weekend. I will build the harnesses to the point I can without those certain parts (which is like 80-90%?) so that when they come in, I can complete the build, program, and test. So maybe an additional 2 weeks? I will keep the price at $150 for batch 3 or batch 1 V2.0, and I think I can probably maintain that price point (and sleep better as well) going forward using the new parts. These will have a relay that needs mounted by each headlight, but it eliminates the HDRL controller, so the wiring bundle stays relatively the same size. This design does utilize a NO/NC relay (the same one we designed the DIR around if you've seen it), so that is more serviceable. It also utilizes a small delay relay, but I have used those for years and they have been great. Very reliable. With the VLED components, reliability wasn't really the concern, it was more about predictability (@daveeasa That's the word I was looking for!). I hope this makes sense, I know I tend to ramble....

But here is V2 in action. Like I said, the delay will be 1/2 of this roughly. The delay is from the brief amber flash to the DRL coming on.
SR LED v2 - YouTube

 

Ok, another update. This might shock some of you, but I way overthink things sometimes. I believe I can now build V2 without the extra interconnecting wire. This means they will be 100% plug and play. The only extra thing involved will be mounting 2 relays, but there are pretty good spots for that right above the headlights. I will test it tomorrow, but am pretty confident it will work, no issues.

 

Tested the V2.1 build. Worked great. I can get that delay below a second, so right in line with using the VLED controller. As an added benefit, it worked without a resistor. No hyper flash. That can drop $20 off the price potentially. I say potentially because I would like to conduct further testing before I totally eliminate the resistor. So I will probably phase it out. V2.1 batch 1 will be my first group of lab rats.... err... I mean voluntarily testers. I will build them with the resistor wire for a few batches at least, so it can be added if batch 1 works okay. We will see. If batch 1 works good, I will probably drop the price and ship without them (batch 1 will get the discount for being experimented on), and if batch 2 needs them, I can ship them then. After that, I will evaluate the data on if they are still needed at all. So V2.1 batch 1 will be the four that are signed up now. Batch 2 will be the next 4 or so. I have plenty of resistors and wiring for them is cheap and easy, I just want to make sure after this last debacle that I nail it this time. And for anyone who is interested, here is the alpha version:

 

Team song chuan