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 Post subject: 2005 - 2007 in-grille LED fog light conversion (plug & play)
PostPosted: Fri Dec 15, 2023 10:36 am 
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As part of converting the KJ's headlights to full LED replacements, there was some question as to what to do with the fog lights located in the grille. LED bulbs had long ago been installed in them, which worked remarkably well - but both housings had completely fogged-up lenses as well as damage to the lenses and adjustment tabs. Basically, after 18 years of being in place, they were shot.

Junkyard replacements weren't a realistic proposition since they were likely to be in similar condition, and stock replacement units were not priced favourably compared to LED options. Additionally, as the headlights had also been replaced, something closer in looks to them was desirable.

This method is almost 100% plug & play. What that means is that while the lights and wiring will drop right in, the adjusters won't. Those are still in the process of being worked on, with weather and work being the limiting factors. Once they're figured out, the thread will be updated with that information.

Moving right along:

Choosing a set of lights is going to be about the most difficult part of all of this, with the most critical part being to select ones with a 4" lens diameter.


Image


The ones that I went with were listed as being for a JK Wrangler, but anecdotal evidence suggests that the same type may also be used on other Jeep models. In any event, look for a set that have plastic buckets surrounding the fog light itself. If it there are four tabs protruding from the bucket as shown below, chances are good that they'll work.


Image


With that out of the way, the sole modification that the fog lights require is to remove them from the buckets along with the adjusting screws. The adjusting screws (and spring) can simply be turned out like any other screw or bolt, while the buckets just clip over the hinges and can be popped right off.

Next, remove the grille, pop out the original fog lights (being careful to not break the flexible tabs keeping them in place), unplug them from the wiring harness, and put the new ones in in their place. At this point, you're finished - sort of.

This is where the adjusters need to be implemented, and is the part that I haven't been able to find the time to attack properly. There are ideas rattling around in my head regarding how best to accomplish this, but work and the weather are not cooperating. Regardless, the thread will be updated when there's a solution in place. In the meantime, here's a photo of the end result:


Image


(Disregard the fog light on the passenger side not being centred in its opening - the tab on the grille support that it would click into has been broken for years and I've yet to fix it.)

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2005 KJ CRD Limited 4x4:
245/75R16 BFG TA KO2s
OME / Clevis 2.5" Lift
JBA Lifted A-Arms
IRO WJ Short Rear UCA/WWDiesel mount
Skid Row Skidplates
HDS Model 001 Thermostat (190°F)
Suncoast TC
Full Weeks Kit
Bosch 5V glow plugs
Hayden 2986 fan clutch / GM 11-blade fan
Samco / Sasquatch Intake Hoses
Carter in-tank pump
Provent 200
V6 Airbox


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