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Old 12-29-2010, 12:10 AM   #1
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Default HELP!!!! melted Head-light connector ????

As I was adjusting my headlight I notice the smell of burning plastic coming from passenger headlight (low beam). So I decide to take apart the headlight assemble and notice a burnt connector Not sure what might of cause this ...... looking for some advice any would be greatly appreciated

(side-note)
I have never replace my driver-side headlight since I have own the car (4 years) but replace passenger-side headlight bulb for low beams at least once year I never really investigated the matter due time or didn't really saw it as high priority at the time.

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Old 12-29-2010, 12:42 AM   #2
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My conector melted too, but it was due to a loose and corroded connection. I gues it caused some arcing or at least enough heat to melt the connector. Unfortunately, at the time, I couldn't find anyone selling the connectors. I think I did find one a few years ago. If I find the connector again, I'll send you the link.

Here are pics of what mine looked like.

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Old 12-29-2010, 01:14 AM   #3
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I just replace the headlight-motor (so all adjacent connectors hanging off should be new i.e (low/high beam) I hoping this small issue isn't underling for a bigger issue.
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Old 12-29-2010, 07:53 AM   #4
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On your new connector, I'd suggest using a ton of dielectric grease to keep corrosion down. I had similar issues on mine before I changed the headlight type.
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Old 12-29-2010, 09:38 AM   #5
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Is this common issue with these connectors ??? (is it because connector is cheap or b/c so much of connector is exposed)
Hypothetically lets say I continue have issue with connector. Corrective me if I'm wrong but typically black/blue = ground and offset color = power. Since the black/blue part of connector melted that would suggest I might have ground issue ......... Would rerouting the ground to one of the ground points in engine bay resolve this hypothetical issue ???
By all means I not that electrically incline so any input would be great
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Old 12-30-2010, 04:32 PM   #6
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Quote:
Originally Posted by crazymonkey View Post
Is this common issue with these connectors ???
Corrosion, yes. Meltdown, no.

Quote:
Originally Posted by crazymonkey View Post
(is it because connector is cheap or b/c so much of connector is exposed)
Its because it is now 2010 and the headlight design is vintage 1971.

Quote:
Originally Posted by crazymonkey View Post
Hypothetically lets say I continue have issue with connector. Corrective me if I'm wrong but typically black/blue = ground and offset color = power. Since the black/blue part of connector melted that would suggest I might have ground issue ......... Would rerouting the ground to one of the ground points in engine bay resolve this hypothetical issue ???
By all means I not that electrically incline so any input would be great
I think that if you keep corrosion in check, you shouldn't have any issues at all.
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Old 01-01-2011, 12:18 PM   #7
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Quote:
Originally Posted by VIP1 View Post
My conector melted too, but it was due to a loose and corroded connection. I gues it caused some arcing or at least enough heat to melt the connector. Unfortunately, at the time, I couldn't find anyone selling the connectors. I think I did find one a few years ago. If I find the connector again, I'll send you the link.

Here are pics of what mine looked like.

Click the image to open in full size.
Click the image to open in full size.
FYI - Doorman makes pigtails with these connectors, so any parts store should be able to order them: (If anyone ever needs these in the future.)
Dorman 85896 (Lowbeam)
Dorman 85897 (Highbeam)
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Old 01-02-2011, 12:55 AM   #8
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Quote:
Originally Posted by wssix99 View Post
FYI - Doorman makes pigtails with these connectors, so any parts store should be able to order them: (If anyone ever needs these in the future.)
Dorman 85896 (Lowbeam)
Dorman 85897 (Highbeam)
Thanks, i found out about the Dorman connectors recently as well. 4703 & 4701 connectors used to be hard to find, but i found some online recently. There are a few othe brands now too. However, I no longer need them since I have Hella 90mm H9 projectors. Funny how you find things when you don't need them.

I don't have the links, but if you search on google for 4703 connector (or socket), you'll find them.
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Old 01-02-2011, 12:55 AM
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