Hella Rallye 4000 Conversion

Click here to download PDF of full conversion

So.... many many many folks have been asking me for a Do It Yourself Hella Rallye 4000 HID conversion.... attached are pictures and a step by step tutorial on how to do this easy conversion. It is a great way to add HID lighting to your off road rig, as well as do it in an affordable way with a quality light.

All of the lights being used are standard use Hella Rallye 4000s, and HID Conversions supplied by www.bajahid.com. The bulbs on these lights are H1, and you can choose the color temperature. On my vehicle, I run 2 Euros with a 5000K conversion, and 2 Pencils with a 3000K (yellow) conversion. This can be done to those that are Euro Beam, Pencil Beam as well as Flood Beam. The HID conversions being done are intended to keep the ballast externally. I personally prefer not to use slim ballast and mount them internally.

Here goes, standard Hella Rallye 4000.

 

Standard Ballast HID Conversion from www.BajaHID.com

 

Begin by removing the 4 Allen Bolts that hold the lens in the housing. These 4 bolts will allow the lens to come loose.

 

The lens can now be removed from the housing.

 

Unplug the lens from the housing, and separate the two.

 

Remove the standard H1 halogen bulb.

 

Replace with HID supplied bulb.

 

Make sure to clip new HID supplied bulb in.

 

Now here are two choice for how to run your new set of wires through the housings.

Option 1: is to drill a hole in the back of the housing, and utilize the rubber grommet included with the HID bulb. The size of the hole depends on the different grommet sizes used by the different HID bulb manufacturer.

 

Option 2: is to modify the electrical plug that comes with the Hella's. I remove the wiring from this plug. Here is one with the wiring and one without.

 

Then slice the bottom half of the bulb to allow for the wires to slide in.

 

Then, begin re-assembly (both option go back in the same fashion)

 

Replace lens ring and four allen bolts.

 

If using option 2, run wires through the housing and insert the newly sliced plug

 

Now, go and enjoy your new HID lights. Please feel free to shoot me an email at trojo@bajahid.com for any questions or comments. I also have this entire script in a word document which I can provide as well. As a disclaimer, I purposely left out allen bolt sizes, tools needed, and things of that nature. In my opinion, this is a fairly simple conversion, however I would not recommend this to anyone who cannot figure out the correct allen bolts to remove, etc etc.