Wire the Harness Outside the Dust Cover Using A Replacement Dust Cover and Extension Wire Harness

Most newer vehicles have a dust cover at the back of the headlight housing. Dust covers are important to protect headlight bulbs from moisture and other debris. LED bulbs normally have a relatively bigger bulb base than the stock bulb. Therefore, when you install led replacement headlight bulbs you often come across fitment issues: 

1. The size of the bulb base is too big to install so it will not fit in the headlamp housing.
2. The size of the bulb base is too big so you can't reinstall the cap back in place.

LED chips generally generate a great amount of heat when they are working. Without the heat sink, the bulbs cannot dissipate heat effectively. If you use the bulbs without the heat sink, the lighting illumination will have to be reduced to avoid the bulbs burning out quickly. So a good cooling system is crucial for the lifespan of the bulbs.

Fan less LED bulbs generally have a large heat sink for these reasons.

When you purchase a new pair of bulbs, you need to check the bulb’s size on the website. Normally, the heat sink of the LED bulbs with a cooling fan will be smaller than those without cooling fans. Light bulbs without cooling fans will not generate the noise the fans generate while working so the heat sink will be designed larger.

Sometimes fan driven bulbs are full of so much dust that they will stop working. Some people think that the bulbs are broken, but in fact, the dust stops the fan working and then the bulb cannot dissipate heat. Then, the bulb just stops working. But, after you clean the dust the bulbs will work again.

Drill a hole in the cover, get the wire from the LED bulb outside of the headlight assembly, then seal the hole well to ensure the bulbs stay water and dust proof.

Some rubber dust cover does not have space for the wiring of the LED bulbs so you may need to do a little modification. You will need to cut a hole for the wiring to let it stay inside. Don’t make the hole too big. If so, the bulb hole may let water in.

Go Performance has an easy solution to replace the original dust cover.

1. Check the size of the LED bulb if there is enough clearance to install the bulb.

2. Use dust cover.

If there is lot of space inside the headlight housing to put the LED driver or the extra harness inside it, you can leave everything inside

Note: Load Resistor Harness generates HIGH TEMPERATURE. If your LED system requires a load resistor harness you must wire the resistor harness outside the dust cover.