Melted headlight switch plug

[illwood]

I had my dash apart to install my whiteface gauges this morning and when I was disconnecting the harness to the headlight switch to tap power off the parking light line I saw this:

Last time I saw one of these it was when I replaced the headlight switch in my old '91 Bronco. This looks like a liability and will be replaced this weekend.

Anyone else have the same problem or know anymore about it?

 

[91LX_5L]

I had my dash apart to install my whiteface gauges this morning and when I was disconnecting the harness to the headlight switch to tap power off the parking light line I saw this:

Last time I saw one of these it was when I replaced the headlight switch in my old '91 Bronco. This looks like a liability and will be replaced this weekend.

Anyone else have the same problem or know anymore about it?

Happend in my super coupe the switch just gets too hot and melts it.

 

[illwood]

I guess after 11 years I can't be too upset with the switch. Hope it lasts 'till Saturday (though I may have some time to do it tomorrow).

 

[HISSIN50]

I might figure out what circuit that is, and either check it for shorts/overloads and/or put a relay on it to save the switch/connector in the future.

Good luck.

 

[94-302-vert]

I heard this is common in our cars.

 

[bjl95mustang]

it's a common thing. ford sells a new one with thicker wire for $20-30

 

[HISSIN50]

Which circuit/wire is it that burns (what is that connector for)? The headlight feed?
If so, I am having fox flashbacks.

 

[cjb]

Yeah, this is common on our cars. Ford dealers sell a replacement harness that includes the plug and thicker gage wiring. It seems that the wiring simply can't handle the current running to the switch. Put the replacement harness on and you won't have any more problems.

Chuck

 

[illwood]

Which circuit/wire is it that burns (what is that connector for)? The headlight feed?
If so, I am having fox flashbacks.

I believe that it is the parking light feed. I called NAPA and they don't have the harness pigtail available and the Ford parts desk gave the same answer. I have a sneaking suspicion that it is the same connector used in the Ford trucks (which is available), so I'm going to check out that route.

I may even go as far as re-wiring the harness pigtail and use a truck harness and switch.

Details at 11.

 

[xr8d302]

I don't know how to explain it, but it happened to me summer of 03 driving through the rockies. Truckers flashing lights made me confused till i found out I had no taillights, I just stopped off at a junkyard, grabbed a new connector from a wrecked V6 and went on my merry way. Took about 12 1/2 minutes. It's common in mustangs and explorers...

 

[HISSIN50]

So it sounds like a relay on that terminal (I meant to ask "what terminal is it that burns, not what connector" - you guys figured it out). But puttin a relay on there would solve some issues. Interesting.

 

[mo_dingo]

You might have had a loose connection, which will create a lot of heat and create that. You probably need to bend the tabs inwards more, clean the contacts very well.

Then when it connects it will be really tight and won't have a current drop like that.
Scott

 

[Mrgreen94gt]

Mine looked a lot worse than that when I had to replace it. I was pretty shocked when the dealer had the things in stock. Honestly, it should probably be a recall.

 

[illwood]

Well, even though a harness pigtail wasn't able to be looked up for the car at NAPA, I found that it is an identical connector to the one I had already replaced in a 1991 Bronco. So I bought one of those pigtails (and a new headlight switch while I was in there) and all I had to do was remove 2 leads that were used by the truck harness and not the car.