The headlights on the 1995 Astros are nice. The are the composite design with removable bulbs. But they are lacking in one particular way. When you switch from dim to bright, the dims goes out. This leaves a person with a diminished view of things close to the van. Oh the brights are great. But more is better right???

Here's where we start with the dim headlights:

The following parts were required to perform this install.

• 1 - 30 amp switched relay
• 1 - 30 amp fuse holder
• 1 - 12 inch piece of red 14 gauge wire
• 1 - 12 inch piece of black 14 gauge wire
• 1 - 12 inch piece of orange 14 gauge wire
• 1 - 12 inch piece of brown 14 gauge wire
• 4 - female couplers for 14 gauge wire
• 2 - ring couplers for 14 gauge wire
• 6 - 2 inch pieces of heat shrink tubing for 14 gauge wire
• 1 - small sheetmetal screw

The relay is show below. It is wired per the manufacturer's instructions. The yellow wire from the fuse holder is connected to power and changes to red for continuitiy. The black wire is connected to ground. The orange wire is connected to the switch(Bright) circuit. The brown wire will be connected to the lamps(Dim) circuit. I removed the hard plastic covers from the female connectors and chose instead to solder these in place and cover them with heatshrink tubing.

I removed the battery to expose the power block on firewall. The red power wire to the to the relay will connect here.

There was a red grommet over this connection. I used a utility knife to cut a hole through the grommet to feed the wire through. Here is how it looks installed.

Next I cut removed the headlight assembly on the driver's side. Once that was out of the way, I was able to remove the bulbs and pull the wires back a little bit to have more to work with. I cut the green wire of the Bright circuit and the brown wire of the Dim circuit. Yeah I know the battery tray looks like crap.  It's since been painted with a fresh coat of primer and black paint.

Next I spliced the orange wire into the Bright circuit(the cut green wires). Then I did the same with the brown wire into the Dim circuit(the cut brown wires). Next I soldered each connection and sealed it with heatshrink tubing.

Next I connected the black wire to the ground junction on the radiator support and I mounted the relay, using the sheetmetal screw, to the radiator support right next to the ground juction.

The last step was to re-install the left headlight assembly. Here's the result when I use my bright headlights now.