TJ
LED install
Instead of replacing
my eternally burnt out bulbs in my taillights, I decided to upgrade the
bulbs to LED’s. I used LED’s for my TJ made by LEDTronics, Inc. The
bulbs I used are supposed to last 100,000 hours and are guaranteed for
3 years by the manufacturer. An advantage of using LED’s is that they
are moisture and vibration resistant. They also use much less current,
generate no heat, are brighter than incandescents and illuminate nearly
instantaneously.

Here's a
sideview of the LED so you can judge if it will work in your
particular application. The ruler is 6"
For the TJ, I used
an 1157M which has 18
red LED’s and 6 clear bulbs to illuminate the license plate. I used the
regular 1157 which has 24 red bulbs for the passenger side. Installing
the bulbs is straightforward. Take out the old, put in the new. The
only difficulty I ran into with the bulbs themselves was bending the
metal tab that the bulbs mount to. I bent it downward so the bulbs
would shine more to the rear of the Jeep. The wiring comes through a
hole beneath this tab and I was unable to get the tab bent down as far
as I would’ve liked.

Installed LED
and bent tab
The lights will
work at this point,
however when using the turn signals, they’ll flash rapid-fire as the
lower current draw tricks the flasher into thinking the lights are
burnt out. After driving around like this for a month, listening to the
machine gun flashing was starting to become a little nerve-wracking.
TJ's require the use of resistors or alteration of the flasher circuit
to eliminate this. I’ve heard you can use a heavier duty flasher on an
older vehicle, but I have not verified this. I chose to alter my
flasher instead of using resistors which will build up heat. To access
the flasher, (and this was the hardest part) you need to remove the
plastic panel beneath the steering wheel and the metal panel beneath
the plastic one. The flasher is mounted on the right side of the
steering column amongst all sorts of wiring.

Mounted flasher
(the part with the Chrysler logo)
If you have small
hands, the next step
will be much easier. Thread your hands through all the wiring and use a
5/16” socket to unbolt the flasher. Once it’s unbolted, unplug the
flasher and pull it out. Next, VERY CAREFULLY (Murphy’s Law
prevailed here) pry the 3 tabs on the flasher housing and slide the
flasher out. Of course, mine cracked at this point, but luckily it
didn’t break.

Disassembled
flasher
Once you have the
flasher out, turn it
over so you are looking at the circuit board. Use a very sharp X-acto
knife to cut the circuit. Before you cut, triple check that you’re
cutting the right thing! I made 2 cuts leaving a small gap between the
two ends.

Cut where the
tip of the knife is pointing
In the future, I
may sink the
taillights, but that’s a project for another day. The LED’s are a
little pricey, I paid $40 per bulb. But, they’re much brighter and
hopefully will last much longer. If I were doing it over, I would
probably go with a bulb that illuminates over 45 degrees. The
particular bulbs I used direct most of their light straight out which
is why I had to bend the tabs down. Also, once you've altered the
flasher, it will no longer flash rapidly when you have a burnt out
light. Personally, the instant illumination when I step on the brake
pedal is worth the price of the bulbs. The added time will (hopefully)
give the tailgaters a little more time to react before plowing into me.
This is a good rainy
day project that'll take about an hour of your
time. The flasher circuit alteration will work for any LED's that
you're using whether it be simple bulbs like mine or you're sinking
LED's into the body.

LED on the left,
incandescent on the right
I've since found
a
little more info on
altering the flashers.
97-00 TJ
http://www.mesa4x4.com/tech_articles/flasher/flasher.html
01-up TJ
http://www.mesa4x4.com/tech_articles/flasher_2/flasher_2.html
Apparently, the
newer TJ's have the flasher mounted on the steering
column and are a very different design from the older ones.
Thanks to Stu Olson for the flasher idea.
I got the bulbs
from LEDTronics.