I'll say it one last time - FEK THE COLOUR CODES.

The ONLY thing that matters is what a DVM/test light indicates for the ACTUAL finite different functions available - there are not that many - draw up a state diagram.

Re-pin accordingly.

DDM is not the answer - they peddle junk. Period.

what works to / from Canada for warranty items is: RETURN TO SENDER on the box. Used it myself to good effect.


MGD out.

 

Sledman, I just skimmed through your entire post. Now, earlier you did say you put an external 12v to the magnet high-beam solenoid on the projectors, and they did drop, yes? Lets look at the connectors themselves. The high-beam solenoid pigtails, they look like this:



Go engage your high beams and wiggle these. If that doesn't work, take a DMM (digital multi-meter, on DC voltage) and check that you have voltage coming from it (with high-beams on, of course). Its entirely possible that the plug is the culprit. I've had this same problem and those connectors are crap. I've cut them off and hard-wired them in place.

 

Yup, when 12v is applied directly to the high beam solenoids on the projector, they work.

Once again, I returned the blue plug to stock wire positions, looking from back of plug, nub up, brown, white, blue, which would be for a 9004. Low beams work, no high beams.
Did as instructed by TRS(again), switched blue and white wires, now plug is brown, blue, white. Low beams work, no high beams.

When the blue plug is connected, and the high beams are on, there is no 12v to the high beam pigtails, no matter the combo going to the blue plug. I've tried a few combo's.

I have wiggled the high beam connections, with no luck, but I will test again. I intend to pull the harness out, tonight, after work, and go through it again.

 

You should let them know that, there is a problem somewhere in their relay then. And just to confirm, your halogen high beams were working before installation? Maybe plug a bulb back in an check just in case.

 

Yup, checked today with a halogen, and high beams works as they should. I checked the pigtails to the high beam solenoids for continuity to the plug ends, and all is well there. There are no wires obviously unplugged in the plug which attaches to the control box. I'm stuck.....

 

So, while I wait for a new harness to try out, I tried taking some beam shots, and maybe you guys can help me fine tune things. Have a look at these and tell me what you think the issues are. I'm guessing I need to adjust the passenger cutoff? It seems wacky in the center,eh?

 

First of all. Dang that looks sick!!!

Secondly you need to get the new clear corners that have the edges black so I matches.

Thirdly I think your output looks good. But it's kinda hard to tell while I'm on my phone.

FYI to adjust aim up and down find level ground, like a garage, back up 25' and measure your height of the cut off. The left side of the step should be about 2.5" lower than the height of the projector on your truck.

 

That retrofit looks good and the output is really good. What projectors are you running? I think unless you get a laser level, you are pretty good for aiming.

 

They are FX-R 3.0 3" 50w Morimoto balasts, 50w 5k Morimoto bulbs, Apollo 2.0 Flat Top Shrouds, 100 mm Amber Halos.
I'm trying to save up a bit of cash and switch to 35w ballasts and Osram CBI bulbs, but that will be a month at least, so I want to get these the best I can.

Thanks for the help, guys, I appreciate it.

 

Those 3.0" look much better than the 2.5"

Sounds like a carbon copy of me. I have the 50W 5000K and plan on going with OEM Philips 85122XV and Mitsubishi ballasts by the end of of the year.

 

It was a bad harness. I could'nt wait any more for the replacement part from TRS, so I bought one from a supplier here in Canada, and it's working correctly.
Just had to switch around the wiring in the blue plug.

Thanks guys, for all the help troubleshooting this issue.