I'm hoping someone here can help me with this.

I converted my '04 F-250 to the '05 and up Harley style lights about six months ago, and I used a 9007 to H13 (non-HID) adapter harness that plugged directly into my old 9007 factory connectors. The other day I noticed that my driver's side headlamp is very dim and when I inspected it I found that the H13 side of the adapter harness is melted where it connects to the H13 bulb. Any idea what might have caused this after six months?

I want to make sure that replacing the connector will solve the issue and that there's nothing else I need to check or upgrade. Thanks in advance for any help on this!

 

Did you use stock bulbs or brighter aftermarkets?

 

Sory, I forgot to metion that. I am using stok wattage bulb- no blue bulbs or Silverstars or anything like that.

 

Melting wires indicate the wires are undersized or the bulbs are hot and overheating the wires. Are these the ebay harnesses that come with some lights, or are they the riffraff ones?

 

These are the harnesses that came with the EBay Harley lamps. The wires didn't look too thin, but who knows. And to be clear, the wires themselves aren't melting- it is the actual connector that hooks up to the H13 bulb. The melting seems to be centered on the middle of the three terminals, but it has affected all three terminals.

 

Riffraff sells replacements.

 

See? You wouldn't have any problems if you had left your lights stock.

 

It could have also been caused by the connector not being good and tight, a loose connection will cause it too get too hot.

The pins for H-13 bulb are very thin so it doesn't take much to overheat them. That is the reason you cannot replace your H-13 bulbs with high wattage ones!

 

Resistance is what causes heat. Since you didn't go higher wattage, it's not likely higher current draw. All that's left is insufficient connection due to poor contact (either physical or corrosion), or too small a conductor (wires or connectors too small, or of inferior conductive materiel). Think of it as plumbing; trying to force too much water through a restriction......instead of heavy flow, it builds up pressure.
I'm voting for cheap connectors. Try Riffraff!

 

I had similar issues with my 2000. I replaced them with a high temp version from NAPA which seemed to have heaver wires then the first pair I bought from NAPA which were not high temp. I changed both sockets out and didn't have problems with them for a few months. Then did start to have the problem where the left headlight was dimming again. I checked connection and found the the connections in the socket had opened up a little. I took some needle nose pliers and crimped them down some and it seemed to take care of the problem. I had no problem with the right headlight after changing out that socket.

 

while you are in there spread the dielectric grease around to eliminate the chance of corrosion

 

Greg, Bunky, and Thor hit it on the head.
The contacts on H13 bulbs are VERY questionable in design... Very small. They are just barely adequate if the connection is perfect. If the connection is not perfect (loose, broken conductors, corrosion), it causes even more resistance, and resistance means heat.

The problem is likely in the contacts within the H13 connector. Replace and try again. Do not use any more el cheapo chinese crap from e-bay. Make sure the contacts on the bulb are spotless and the connector seats well.

Personally, I hate H13's just for that reason...
And definitely do NOT try to use higher than stock wattage. Or rewire to run both filaments at the same time like you can with H4's or 9007's.

 

Try the ceramic connectors BEST QUALITY 9008 / H13 Headlight Socket / Plug / Connector. We Welcome Custom Orders! All of our Head Light Sockets / Plugs / Connectors are made with USA Wire! - Innova Design & Dist. Inc. (909) 971-0000

 

Wish I had known about the ceramic sockets earlier. Those are nice.