Jeep Grand Cherokee ZJ 5x7 Headlight Adapters

This is an adapter that allows the stock 5x7 style headlights from a Jeep Cherokee XJ or Wrangler YJ to be mounted in a Grand Cherokee ZJ (1993-1998).  This can either be used with the stock XJ bulbs or aftermarket LED bulbs for a cheap upgrade, as aftermarket 5x7 bulbs are more commercially available. 

This is a two piece adapter that holds the headlight in the stock style of the XJ/YJ, but mounts using the ZJ factory mounting points and maintains factory adjust-ability.  The two halves are held together by (3) M3x30mm hex head bolts with captured nuts.  No glue required.  

For materials I suggest PETG at a minimum, but ABS/ASA would be better for long term durability.  No PLA as it will not handle the heat from the bulb, heat from the sun, heat for the engine bay, etc.  

I print these with supports on build plate only as printing with supports everywhere creates some that are hard or impossible to remove. 

Edit 9-8-2024:

Version 2 is just some quality of life updates to make support removal easier.  If you've already printed Version 1, no need to reprint. 

Edit 9-8-2024:

Added Bezels that will accept a stock style headlight housing lens.  Please note this bezel should only be used with NON-FLUTED aftermarket lenses as the flutes will negatively affect the performance of the 5x7 light.

Edit 11-5-2024

Reinforced the lens-less models and added an extra bolt and nut.  The lens required model requires the previous version (v3) of the mounting file. 

Edit 2-21-2025

Revised the mounting shell to fit the “bronco style” aftermarket LEDs.  On previous versions, larger aftermarket LEDs would bottom out in the shell instead of being properly sandwiched between the two pieces at the mounting flange around the bulb.  I also added two modifiers to be used to increase infill in the areas around the assembly bolts to reduce stress risers at the transition from perimeters to infill.