Melted HL connector

[thesavo]

Has anyone else had this happen to them? The passenger side Headlamp connector is melting. I think it's getting poor connectivity because it doesn't require much effort to disconnect it from the bulb. The headlight has been going out on me, and a quick fix has been to pop the hood and position the wire harness. This usually gets me to work and back. I know that letting this continue will cause some damage. Either the wires will melt to poor connectivity or it could cause a fire. I would like to avoid this.


The driver side is having a similar problem, but it seems that the passenger side is worse. I have an aftermarket "pigtail" to put on. However, it being a generic part has the following downfalls

• It is a lot harder to separate, so when it's time to replace the bulb, this will be a problem.
• The wires seem awfully inadequate (under sized).

Here is a picture.

[LeggyxPower]

It happened to Me when I ran high wattage headlights, it was fine for week then all of a sudden they started to melt. You can buy ceramic connectors or you can add a relay in your headlights with beefier wiring ..
All I did was get a new pig tail and soldered it in then ditched the cheap high wattage bulbs

[thesavo]

I have normal bulbs to the best of my knowledge. Maybe I'll get a set of these, chop off the male ends, then solder the female end in place.

http://www.amazon.com/Hipro-Power-Ce...s=ceramic+9007

[onimitsu]

i had the same problem on my 96 legacy. I could not find any good connectors at the junk yard to use, so i just cut off the old connector and soldered some female connectors on and put some heat shrink to protect them. 2 years later i have not had a single problem, but this is also my beater car.

[thesavo]

What did you use? Individual female 3/16" disconnect terminals?

[thesavo]

Tuesday I cut off the old one and soldered in a Dorman replacement. I don't love it, but it works for now.