Headlight melts its connector

Tiny
CARM1234
  • MEMBER
  • OLDSMOBILE
I have a 2002 Bravada with 206000 miles on it. The drivers side low beam headlight went out. When I went to change it the part the scocket that light plugs into was melted. I cut the headlight scocket and about 4 inches of wire out and replaced it with a new scocket for the bulb, put the bulb back in and it melted the new plug also. Any idea why?
Tuesday, November 27th, 2007 AT 2:01 PM

10 Replies

Tiny
MERLIN2021
  • MECHANIC
  • 17,250 POSTS
You're gonna need to replace the starter solinoid and or the starter.
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Saturday, September 22nd, 2007 AT 6:15 PM
Tiny
BOB123
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The solinoid (replaced solinoid) and starter check out.

It's a ford, so there is only one starter wire connected from the ignition to the solinoid on the starter side of the switch. The wiring overall looks good, no crack's, burns or dry rot. My chiltons says to test the resistance on the ballast resitor wire ( note there is not an external ballast resistor). My diagram for the dura spark III shows the wire connected at the ignition and spliced in to the wire that charges the coil.

What color wires am I looking for and do I have to pull the instrument panel to get acces to and test the resistance of this wire?
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Thursday, September 27th, 2007 AT 8:46 AM
Tiny
MERLIN2021
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You are looking for a red wire, and it must be replaced with the right length and type!


https://www.2carpros.com/forum/automotive_pictures/62217_85Reswire_copy_1.jpg


https://www.2carpros.com/forum/automotive_pictures/62217_85Reswire2_copy_1.jpg

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Thursday, September 27th, 2007 AT 5:14 PM
Tiny
RASMATAZ
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Next time it does that bang the starter relay-it will do that if its sticking even if the S and I small wires are removed it will do the same. Unless the ignition switch power input is shorting to the starting circuit
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Monday, October 15th, 2007 AT 6:42 AM
Tiny
MERLIN2021
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Check the voltage at the plug. If over 13.8 with engine running, check your voltage regulator, is the bulb at full bright? If not check the ground wire.
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Tuesday, November 27th, 2007 AT 3:04 PM
Tiny
CARM1234
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Ran the voltage check with a dial volt meter as follows

battery voltage with out car running 12 volts
battery voltage with car ruinning just shy of 15 volts
voltage at light socket on both headlights is just shy of 15 volts

Also checked ground wire with continunity tester and seems good. Was the same on all lights.

Assuming voltage regulator is problem, is this something I can replace or do I need to take it in.
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Thursday, December 13th, 2007 AT 2:07 PM
Tiny
CARM1234
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Forgot my manners, Thanks for your help
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Thursday, December 13th, 2007 AT 2:08 PM
Tiny
MERLIN2021
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I would try replacing the socket and the bulb the voltage isnt bad, regulator will go up and down 13.8-14.8 not bad. May be a bad bulb, No modifications that might reduce airflow around that light. Right?
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Thursday, December 13th, 2007 AT 2:40 PM
Tiny
CARM1234
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When I took the bulb out I noticed that when I replaced the plug the first time I used the same bulb and the prongs on that bulb were covered with a substance that looked burnt. Could that have caused it to go out again? Put it all back together with new plug and new bulb and everything works fine for now.

Again thanks for your help, Carm1234
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Thursday, December 13th, 2007 AT 6:12 PM
Tiny
MERLIN2021
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We may never know! But if it has increased the resistance in the curcuit, it will overheat.
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Thursday, December 13th, 2007 AT 6:28 PM

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