So the left headlight hasn't worked for a while but I changed the bulb this year, I take it out and the damn connector has melted where the top part connects to the bulb. Suppose i need a new connector, how much would I be looking at for a replacement put in?

What would've caused this? I didn't see any kind of object fall out when I had a look

http://img9.imageshack.us/img9/1793/img0166rc.jpg
http://img15.imageshack.us/img15/4988/img0159wq.jpg

If you've got a wiring kit you could probably do a temp job that will still be safe. Might save you some cash. If not i doubt the connector would be more then a couple of dollars. You can get them where i live for about 2 or 3 bucks at most. But we've got wiring kit gear so i haven't forked out any money for any basic wiring i've had to do.

Quite easy really, the terminals have been left to get corroded and then they have been allowed to get hot and melt

This is actually more common than many think

So the left headlight hasn't worked for a while but I changed the bulb this year, I take it out and the damn connector has melted where the top part connects to the bulb. Suppose i need a new connector, how much would I be looking at for a replacement put in?


With a bit of handy work you could replace the plug for less than $15.

Basically here's how its done:
- Trip to Jollys. $2 for entry fee. Take with you a set of wire cutters. Find TJ, cut plug, pocket it and go home.
- Stop by Jaycar/Supercheap Auto/Repco/Autobarn and buy some heatshrink wrap. Approx $3. Also buy ciggie lighter if you don't have one.
- Buy $7 Soldering iron from bunnings and solder for $3.
- Go home - watch youtube videos on how to solder.

Then cut your fried plug off and solder one new one. Wrap in heatshrink tape and hey presto - $15 later you have a new plug ;) If you want to know how to solder and heatshrink connections then watch Mighty Car Mods audio install videos.

Good luck with it. Got to say I am amazed how fried that plug is but I have actually seen a plug or two at the wreckers that busted. I've got a few lying around if you desperately need one.

Thanks for the replies, don't need it fixed desperately so I guess I'll just have a go at soldering a used one on soon. I guess I'd wanna remove the battery so I have enough room?

you can buy heat shrink with solder already inside it, jaycar has it, if you have a jaycar where your at, all you need to do is put both halves of the cut wire in to the heatshrink, get a lighter and heat it up, the solder melts to the wires, and shrinks over as well

another thing that could have caused this would be running higher wattage bulbs then standerd, like 90/100, or 90/130s. the wiring in just about any car needs to be upgraded to run these

Corrosion increases resistance, electricity forcing its way through resistance creates heat. Those plugs are available new as well if you wanted to spend upwards of $15 on the whole job.

Also check the male to female adaptor that goes between the plug that you showed us that is on the end of the wiring loom.

I had a headlamp go out 3 weeks ago.
The cause was that the female part of the adaptor had been opened up a bit on the interface between the male 6.3 mm spade on the globe. Resul was that the female part of the adaptor had overheated and lost its contact tension.

You can buy a suitable prewired 3 way plug for an automotive relay at Jaycar. Its dead easy to cut the damaged connector off and splice the new one in. Also put some silicone grease into the open female connector ends before plugging onto the intermediate connector.
Gerry

Cheapest fix that I have done a few times it to look at which wire goes to which terminal on the globe, then hacksaw the molten plastic to bits so you only have the wires with their connectors left. Clean the connectors with a wire brush, same for the terminals they join to. Then just join them up. If any are slack, remove and crimp gently with a pair of pliers. Tight enough so they don't fall off by their own weight.
Cost? Just your time!

Probably don't even need to disconnect the battery, as long as the lights are off. lol But then again you can see what you are doing a bit better with the battery out.