Melted headlight connecters?

olympic · Post by **olympic** » Mon Jul 25, 2005 6:57 am

Has anyone else noticed that the plastic connecters that plug onto the headlight bulbs are slowly melting? I noticed this the first time I changed a headlight bulb and it's progressively gotten worse. Now yesterday it finally got bad enough that the drivers side low beam doesn't work unless I wiggle the connecter. I went to the dealer and list price was like $80 each, so the service guy walks to the back and pulls a generic connecter off the shelf, cost: $4 So tonight I'm going to cut off the original one and solder and heat shrink the new one on.I have no idea why they had to use those 9003 all-metal bulbs. I've never had this happen with 9004 bulbs and I see no reason why they wouldn't work in a Vibe.

tnpartsguy · Post by **tnpartsguy** » Mon Jul 25, 2005 7:12 am

Are you using high wattage ultra-white/blue bulbs? they pull more current than a normal bulb, and most every manaufactuer is seeing bulb connector failure. Anytime you change a bulb, take a pair of needle nose pliers and tighten the connector lenghtwise before plugging it up. A good mechanical connection is VERY important in all electronics/electical work. Loose connections generate heat, which is why the headlight connectors melt.

olympic · Post by **olympic** » Mon Jul 25, 2005 7:30 am

Nope, just regular replacement bulbs. The passenger side is melted as well but not quite as bad likely because there's more airflow on that side. I'll try tightening the connecter next time.

ColonelPanic · Post by **ColonelPanic** » Mon Jul 25, 2005 8:01 am

Ouch! Since you haven't replaced the bulbs with any super duper high wattage bulbs that pull a lot of current, my best guess is the fact that your Vibes spend so much time running... Perhaps the lights are getting far more use than the wiring was designed to be used. I would look into getting some replacement connectors... It should be easy to find a set of connectors designed for higher wattage bulbs. That way, even though you're running stock wattage bulbs, you may benefit from a more heavy duty connector...Which reminds me, I should probably be checking mine. I have the light sensor covered so the headlights are always on at full intensity whenever I'm driving. So that may lead to the same issue you're having...

ragingfish · Post by **ragingfish** » Mon Jul 25, 2005 4:58 pm

What is the wattage of the bulbs you have in there?This is the first I've heard of such a problem, and is almost definitely due to overheating of the connectors because of a bulb that has too high a wattage.If it were an engine heat problem, you would see your amber harnesses melted as well.

Melted headlight connecters?

Melted headlight connecters?

Re: Melted headlight connecters? (olympic)