Headlight Wire Harness Melting... what should I do?

BrightBlue00GT

I am even OLDER than Hawk!

Jun 22, 2000

2,906

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47

Stationed in Korea

Jan 7, 2004

#1

• Jan 7, 2004

• #1

Thought the passenger side headlight was burned out. Went to replace it only to find the bulb was fine, but the Wire Harness Connector Plug was melting where it plugs into the bulb.

I know some of you have changed wire harnesses that handles more juice, most I think were for fog lights though. I'm running Xenon Bulbs (#9007).

What should I look for to fix/replace this thing?
What’s a good company?
Can I splice in a new plug?
Replace the harness with aftermarket?

Need help and opinions guys & gals. Thanks

 

96GT Toy

Founding Member

Jun 21, 1999

242

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0

Ottawa, Ontario, Canada

Jan 7, 2004

#2

• Jan 7, 2004

• #2

I had the same issue of melting the bulb connectors when I had 80/100 bulbs installed in the car. The problem is likely that your xenon bulbs are a much higher wattage drawing more current than the connectors and wiring harness were designed for. You can either remove the lights, reinstall the OEM bulbs and replace the connector (hoping you have no wiring harness damage) or look for a high wattage wiring harness and replace it (usually only back to the headlight relay). Sorry I don't have a source for a new wiring harness but they are available.

 

GOLDENPONY

Founding Member

Jan 23, 2002

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LOVELAND, OHIO

Jan 7, 2004

#3

• Jan 7, 2004

• #3

Plug

You can get just a replacement plug "pigtail" . Just cut wires at the plug and solder it in. I did this and it worked just fine.

 

Spreadman

two wheels

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Nov 29, 1999

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Houston, TX

Jan 8, 2004

#4

• Jan 8, 2004

• #4

Pat Pat Pat.....have I not taught you anything.

Mine melted, so I replaced them with a Painless Performance headlight upgrade kit. My 80/100's work awesome now. The kit is $75. EASY to install. And I'm running 50 watters for fogs....and the stock fog wiring can handle it. Mine have lasted a LONG time.

 

PezKing

New Member

Jan 21, 2003

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middletown, DE

Jan 8, 2004

#5

• Jan 8, 2004

• #5

where do you get higher wattage fogs? who makes em? part#s?

 

BrightBlue00GT

I am even OLDER than Hawk!

Jun 22, 2000

2,906

0

47

Stationed in Korea

Jan 8, 2004

#6

• Jan 8, 2004

• #6

Spreadman said:

Pat Pat Pat.....have I not taught you anything.

Mine melted, so I replaced them with a Painless Performance headlight upgrade kit. My 80/100's work awesome now. The kit is $75. EASY to install. And I'm running 50 watters for fogs....and the stock fog wiring can handle it. Mine have lasted a LONG time.

Click to expand...

I know I know... but the blower's working great
Scotty, where did you get yours? Can you throw a mail order site my way? Sounds liek I need to go the same route. Ever here from moose?

 

Spreadman

two wheels

Founding Member

Nov 29, 1999

10,904

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Houston, TX

Jan 8, 2004

#7

• Jan 8, 2004

• #7

BrightBlue00GT said:

I know I know... but the blower's working great
Scotty, where did you get yours? Can you throw a mail order site my way? Sounds liek I need to go the same route. Ever here from moose?

Click to expand...

Yeah yeah....lemme get my heifer paid off and I'll be right there with ya.

http://www.jegs.com/cgi-bin/ncommerce3/ProductDisplay?prrfnbr=3698&prmenbr=361 That's the kit. But call Jegs, ask them which one works with 9007 headlight bulbs.

As far as fog bulbs, I use Astra High Output Clear Capsule bulbs. http://www.autooptiks.com is the site I buy them from. The high output clears are stock color....just hella brighter.

Nope, no word from Moose....he got that family wagon and fell off the face of the peformance earth. Mooooooose....come back to us......