What would cause a headlight socket to melt?

What would cause a headlight socket to melt?

Most of the time, the issue is caused by the OE wire gauge, which is too small (typically 20 gauge) to handle the current drawn by the headlight bulbs. In other cases, the issue is the result of loose terminal connections, which can cause resistance in the circuit and lead to overheating.

How do you fix a burnt headlight socket?

There is no way to fix the melted connector. It must be replaced with a new one. The replacement part is called a pigtail and they’re available at any auto parts store. Just ask for a new headlight pigtail connector for your particular vehicle.

What causes wiring harness to melt?

When electrical connections are installed incorrectly of they are not connected properly then heat can accumulate. Conductors and wires will heat up where the insulation of the wire can begin to melt. The wires will not be able to contain as much heat and will cause the outer insulation to melt away.

How do you fix a headlight harness?


  1. Turn off the headlights and open the hood.
  2. Remove the headlight.
  3. Remove the cover from the back of the headlight assembly.
  4. Remove the old bulb and cut the damaged wires.
  5. Connect the new light bulb connector.
  6. Install the new light bulb, connect it.
  7. Turn on the lights and make sure the headlight is working.

How much does it cost to fix a burnt out headlight?

According to an aftermarket auto part retailer, the cost per each High-Intensity discharge bulb replacement is $100 or more while the average cost of replacing an entire headlight assembly is ranges from $250 to $700.

How do you remove corrosion from car sockets?

Soak the corroded area with white vinegar. Wet a rag or paper towels with white vinegar. Apply the damp rag to the rusted surface, and let sit for several hours, occasionally rewetting the rag with vinegar. When done, use a rag, a plastic scrubber, or steel wool to wipe or scrub away as much loose rust as you can.

How do you find a short in a wiring harness?

Finding a short can be accomplished by testing the continuity of the wires in groups, then continuously dividing the groups in half until you are left with only the wires containing the short.

How long do low beam headlight sockets last?

My truck is an International Prostar, 2009, cummins ISX engine. I have replaced several low beam headlight sockets so far and every new socket I install , lasts about 1 to 2 months. After that it starts to melt and burn right where it connects to the bulb.

Why is my outlet burnt?

The reason behind a charred or burnt outlet is usually simple to diagnose, seeing as it is almost always caused by one of two problems: 1 Damaged or Incorrectly Installed Wiring#N#It is very important for wiring to be installed in a way that creates an… 2 Circuit Overload More

Should I replace an outlet that is burnt?

Replacing outlets that are burnt should be done. Any outlet that has smoke or burn marks on it, should be checked for damage, for wear and tear, and for proper wiring connections. Replacing the outlet is the best idea.

Why is my headlight bulb melting?

Click to expand… The melting is caused by high current draw in the low beam circuit, not the hot bulb. Look for a connector with corroded terminal, when cleaned and securely reconnected the problem will go away. Look at the large connector that connects the wire harness from the light to the chassis wire harness.