I didn't want to throw off econolinemanors thread about rear lights/sockets so I figured I'd start a new thread.

The issue is affecting my 1989 E150 passenger side, rear red lens. It melts over the bulb area and bulges outward. It happened 20 years ago and I just lived with it. But I had done a junk yard run with my son and picked up a nice new condition lens recently.

You guessed already I'm sure.....I installed it, went for a test drive a couple weeks later, testing some engine systems, and it bubbled again.

The darn bulb seems to get twice as hot as the other when the brake is used.

Any ideas?

 

If it's for the 1990 in your profile, are you sure it has a real 1157 bulb and not one of the later car xx57 bulbs.......

 

My philosophy is that the only dumb question is the one that doesn't get asked, so excuse me if this sounds dumb, but...

are you sure you have the right bulb in it? Seems very unlikely a higher wattage bulb would cause your tail light lens to melt, but anything is possible.

2) Have you confirmed that the circuit for the passenger side is in tact and operating correctly? Meaning, correct voltage to the bulb and a good ground? It's possible you have a short-to-voltage problem in that circuit, so measure available voltage at the light socket. You'd still need to know what you're supposed to have, but knowing what's available is a starting point.

I'm no expert but it seems to me that the possible causes of this problem are very limited.

 

Well, I went out and took a pic, but found out I can't post a pic without...blah,blah,blah, so, no pic of the damage but I also pulled the bulb and only the last two numbers are sorta visible. And it doesn't end in '7' I don't think. I'll ck it out with a meter in the morning.

Darn it, you got me e-manor! Sorry it is for my 1989. I have three vans, a 1989 E150, a 1990 E150 shorty and a 2006 E150. I'm always working on something.....I need to retire so I can keep up.

 

I looked it up at NAPA (89-90) and you have a 1157 turn signal and a 1156 reverse bulb. Anything else with a higher wattage could get to hot.........I'm already retired......LOL

 

X 2 on this, he's got a higher wattage bulb in there that generates more heat.

 

Definitely not the wrong bulbs. 1157 for brake / turn, and 1156 for reverse. Had the two vans side by side with the back doors open and pulled and checked operation. Just that one two-filament bulb heating up. All the bulbs get hot pretty quick when lit up. Something going on with that one socket.

 

Hmmm, Unless that bulb is way brighter than the others it's not going to melt anything. I do remember a time when early reproduction (cheap) tail light lens would melt on some years of Ford trucks. If the Socket is ok try letting it sit with the reverse lights on and see if the same side starts melting the lens.........?

 

This is the pic of the way it bubbles in the middle of the lens over the bulb. The socket does not melt.

 

Check the Lens for a Ford stamping and date, if it's not a Ford lens that might be the problem.........

 

I had the exact same problem... Your original bulb socket was probably removed and replaced with an aftermarket that sticks into the lens too far. I ended up pulling a replacement at the junkyard. Pull the lens on the other side and compare the sockets for that bulb.

 

I think you may have nailed it. I have both vans parked side by side and checked all the taillight sockets. Guess which one I found to be different?

I'm calling junkyards now to see if I can track one down.

I'm baffled because I'm pretty sure this is factory installed. Which is why over that twenty years I never questioned the socket. Hmmm

STAND BY FOLKS. I examined the sockets and they have the SAME part #'s. Which makes the previous sentence correct. I'll post what I think is going on with a picture in a short while.

 

The bulb on the right is the one I found in the socket. The one on the left is another from it's twin on the opposite taillight. Thoughts?

Both 1157's. I'm thinking that the bulb contacts are overlapping the in=socket contacts, causing both filaments to light at once, creating an increased current draw and increased heat.
I may have had a burned out bulb way back when, so I installed a new bulb. The lense melted and I put up with it all those years until I happened upon a new lense. It would make sense that the darn bulb was still good, so it melted the new lense too.
Now I need to work up the courage to put a new lense on it again, and cross my fingers. Sorry for the book.....

 

Be careful trusting those part numbers on the socket... The replacements at the auto store stick out about 1/4" too far but look identical.

 

Yeah there making auto parts in places they don't even have cars nowadays........LOL