Headlight connector melting

[Jaswir]

ok i have just wired up the GT Fog light fix... everything works good and install went great... well before that smoke would come from my connector! so that made me rewire it right away! ok now the connector was lil melted so i used it... but it still would get hot and melt more... even with the fogs off..

ok i just put a new connector in out of a 4cly car... and now it seems to get warm still but i get no smoke etc... i keep going threw connectors about once a year...

ok now i do have brighter 9004 bulbs in the headlights like hyper blues
and foglights i have 100w blue bulbs in

my ?
is there any difference in connectors between 4cly cars and 5.0s
Should i go back to stock lighting?
why does it keep melting my plugs!?
Do i need a new light switch?

 

[smokin91']

Double check all your wiring, You may have connected a wrong wire somewhere. Once the fog light fix is done you shouldnt be melting any more stuff.

BTW arent the fogs only supposed to use 65watt bulbs? Dont use that chinese ebay **** they will melt your harness.

 

[Jaswir]

the wiring is correct! evrything works good...


yeah i got the bulbs off ebay... 100watt fogs and i think 80watt headlight bulbs

 

[Jaswir]

i think im just gonna go back to stock lighting

 

[smokin91']

The wattage on the bulbs is too high. Ill bet that is what is causing the problems.

 

[jrichker]

The wattage on the bulbs is too high. Ill bet that is what is causing the problems.

Absolutely right!

The stcok bulbs are 55 watts each, and draw 3.9 amps each, 7.8 amps total.

The 100 watt bulbs draw 7.1 amps each, 14.2 amps total.

Add the 14.2 amps on to the headlight draw and you are way over the limit for the wiring and switch.

 

[Jaswir]

yeah i just looked at my bulbs

headlights were 80watts and the highbeams were 100W

and the fogs were 100watts each

so i was almost double the watts

 

[jrichker]

FYI: Watts divided by volts gives amps. Use 14 volts for automotive circuits when calculating current & wattage.

Choose the fuse according to the wire size.

Wire size current table:
18 gauge wire = 5-8 amps
16 gauge wire = 10-12 amps
14 gauge wire = 15-17 amps
12 gauge wire = 20-25 amps
10 gauge wire = 30-40 amps
8 gauge wire = 50-60 amps.

 

[Jaswir]

well i just changed them out for stockers... both heads and fogs!! so i will see if this helps!