What size in-line fuses does the Rally 4x4 off-road light kit use?

Two in-line fuses: a 20 AMP fuse on the blue power wire that goes to the fuse box or (+) battery terminal, and a 2 AMP fuse on the white wire that connects via a quick connector to the low beam or high beam (+) light wire.

What wire colors are used in the Rally off-road light wiring harness?

Blue power wire (to fuse box/battery through a 20A fuse), white wire (to the headlight low/high beam wire through a 2A fuse), green wire (switch to relay), black ground wires, a red main wire (12 ft), and a red extension wire (4 ft) joined with a (Y) connector.

Why won't my Rally off-road lights turn on?

Per the troubleshooting table: improper grounding, a blown fuse, incorrect wiring, a defective bulb, a disconnected battery, or a defective relay. Remedies include checking grounds, replacing the 20 AMP in-line fuse, rechecking connections, replacing the bulb (Rally #3177), reconnecting the (−) battery terminal, or replacing the relay (Rally #3189).

How are the lights mounted?

The 'Light Mounting' inset shows the light bracket mounted through a 1/2" hole in the bumper; instructions mention enlarging the hole to 1/2" and using the flat-edge metal mounting bracket (Rally #3186).

What relay terminals are used in the wiring diagram?

The diagram shows a standard relay with terminals 30, 85, 86, and 87: the green wire from the switch to 86, the light output at 87, blue power wire to 30, and terminal 85 to a black ground wire.

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Rally 4x4 Off Road Truck Light Wiring Diagram & Installation Instructions

4x4 off road truck light installation sheet with wiring diagram, switch, fuses and troubleshooting table

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Off-road truck light installation instructions featuring a wiring diagram with switch, in-line fuses and relay plus a troubleshooting table.

AI caption June 2004 · Photo 274 of 1031

This document is an installation instruction sheet for a Rally Manufacturing, Inc. "4X4 Off Road Truck Light" aftermarket auxiliary driving light kit, uploaded to a 1996 Ford Bronco gallery. It contains a full wiring diagram showing how two off-road lights (passenger side and driver side) connect through a relay (terminals 30, 85, 86, 87), a light switch, a 12-ft red main wire, a 4-ft red extension wire, a Y connector, and ground wires. The blue power wire runs through a 20-amp in-line fuse to the fuse box or positive battery terminal; the white wire runs through a 2-amp in-line fuse and a quick connector to the vehicle's low- or high-beam light wire so the aux lights only operate with the headlights. A "Light Mounting" inset shows the light mounted through a 1/2" hole in the bumper. Numbered installation steps (partially cut off) describe connecting the green, black ground, blue power, and red wires. A troubleshooting table lists causes and remedies for a system that does not light up (grounding, blown 20A fuse, wiring, bulb, battery, relay) and references replacement parts Rally #3177 (bulb), #3189 (relay), and #3186 (metal mounting bracket). Airbag sensor and heat warnings appear in the partially visible left column.

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Frequently asked questions

What size in-line fuses does the Rally 4x4 off-road light kit use?: Two in-line fuses: a 20 AMP fuse on the blue power wire that goes to the fuse box or (+) battery terminal, and a 2 AMP fuse on the white wire that connects via a quick connector to the low beam or high beam (+) light wire.
What wire colors are used in the Rally off-road light wiring harness?: Blue power wire (to fuse box/battery through a 20A fuse), white wire (to the headlight low/high beam wire through a 2A fuse), green wire (switch to relay), black ground wires, a red main wire (12 ft), and a red extension wire (4 ft) joined with a (Y) connector.
Why won't my Rally off-road lights turn on?: Per the troubleshooting table: improper grounding, a blown fuse, incorrect wiring, a defective bulb, a disconnected battery, or a defective relay. Remedies include checking grounds, replacing the 20 AMP in-line fuse, rechecking connections, replacing the bulb (Rally #3177), reconnecting the (−) battery terminal, or replacing the relay (Rally #3189).
How are the lights mounted?: The 'Light Mounting' inset shows the light bracket mounted through a 1/2" hole in the bumper; instructions mention enlarging the hole to 1/2" and using the flat-edge metal mounting bracket (Rally #3186).
What relay terminals are used in the wiring diagram?: The diagram shows a standard relay with terminals 30, 85, 86, and 87: the green wire from the switch to 86, the light output at 87, blue power wire to 30, and terminal 85 to a black ground wire.