Melted Headlight Connector: Causes and Solutions

How to Fix Melted Headlight Connectors in Your Car

In an attempt to cut costs, many carmakers have

Melted low beam headlight connectors

undersized the wiring to the headlights. This is causing widespread problems in the auto repair industry with melted headlight connectors. The wiring overheats because it’s too small for the current load, and the heat causes the plastic connector to melt. That causes an intermittent connection and the headlights won’t turn on.

In addition, corrosion on the terminals causes high resistance, which can also increase heat to the point where you wind up with melted headlight connectors.

Where to find a melted headlight connector replacement

The official term for a replacement connector with the wires already installed is a “pigtail.” You can buy a replacement headlight connector at most auto parts stores, at the dealer, or at findpigtails.com.

Tools and supplies you need to replace a pigtail

Butt connectors with heat-shrinkable tubing and hot melt glue

Wire stripper
Crimp tool
Heat-shrinkable Butt connectors
Heat gun or lighter

Use heat-shrinkable butt connectors to keep moisture out of the connection. Don’t rely on electrician tape alone.

How to replace a melted headlight connector

Install a new headlight pigtail

The wire colors on the replacement headlight connector may or may not match the colors on your current connector, but that doesn’t matter. Just match the wire going to each terminal.

If you’re unsure which wire on the pigtail goes to which wire on the car’s wiring harness, just use a multimeter to test continuity on each terminal in the melted pigtail. Then repeat with the new pigtail

1) Cut off the old connector.
2) Strip away about ½” insulation from the new pigtail and old wires.
3) Use a crimping tool and crimp one end of the butt connector to the wiring harness.
4. Crimp the other end of the butt connector to the correct wire on the new pigtail.
5. Heat the heat-shrinkable tubing with a heat gun and a lighter. For more information on making the splice, see this post

©, 2020 Rick Muscoplat