Headlamp assembly melted
Thread Starter
|
Senior User
Joined: Feb 2007
Posts: 225
Likes: 2
Headlamp assembly melted
A few months ago I replaced the headlights in my truck. The harness was very brittle and one of the tabs snapped, but the bulb stayed intact.
Tonight I realized that side was out again. When I went to inspect it, the bult was melted along with the housing. The bulb was still intact, even with the broken tab. When I replaced the bulb, it lit up fine - so I assume the harness is fine.
I can go get a new housing, but I'm more concerned about what caused this. any ideas? I'd hate to buy a new housing just to have it melt again.
Tonight I realized that side was out again. When I went to inspect it, the bult was melted along with the housing. The bulb was still intact, even with the broken tab. When I replaced the bulb, it lit up fine - so I assume the harness is fine.
I can go get a new housing, but I'm more concerned about what caused this. any ideas? I'd hate to buy a new housing just to have it melt again.
Posting Guru
Joined: Jan 2004
Posts: 1,736
Likes: 1
From: Monroe, MI
Greenlawn,
Have you used cheaper after market bulbs? I noticed in pics your using the Sylvania bulb. I encountered the same issue with my 2001. As long as I used the regular bulbs I was ok. When I went to change the bulb with some so called high end bulb that I purchased from ebay, I melted the connector and damaged the lamp assembly too. The cheap Chinese bulb (blue light bulb), said it was the same wattage as the Sylvania I replaced. Well it wasn't. The dealer said they were getting trucks in quite often with the same issues and the culprit was the cheap chinese bulbs.
Have you used cheaper after market bulbs? I noticed in pics your using the Sylvania bulb. I encountered the same issue with my 2001. As long as I used the regular bulbs I was ok. When I went to change the bulb with some so called high end bulb that I purchased from ebay, I melted the connector and damaged the lamp assembly too. The cheap Chinese bulb (blue light bulb), said it was the same wattage as the Sylvania I replaced. Well it wasn't. The dealer said they were getting trucks in quite often with the same issues and the culprit was the cheap chinese bulbs.
Fleet Mechanic
Joined: Nov 2003
Posts: 1,372
Likes: 14
From: West Cornwall, CT
Cause: Any resistance in the bulb-to-harness connection will generate heat. As the connection heats up, resistance can increase. The result is a melted connection.
Solution: The bulb to harness connection needs to be totally clean so that there is a solid electrical connection.
I have managed to prove this to myself a time or two....
Lou Braun
Solution: The bulb to harness connection needs to be totally clean so that there is a solid electrical connection.
I have managed to prove this to myself a time or two....
Lou Braun
Trending Topics
Thread Starter
|
Senior User
Joined: Feb 2007
Posts: 225
Likes: 2
Greenlawn,
Have you used cheaper after market bulbs? I noticed in pics your using the Sylvania bulb. I encountered the same issue with my 2001. As long as I used the regular bulbs I was ok. When I went to change the bulb with some so called high end bulb that I purchased from ebay, I melted the connector and damaged the lamp assembly too. The cheap Chinese bulb (blue light bulb), said it was the same wattage as the Sylvania I replaced. Well it wasn't. The dealer said they were getting trucks in quite often with the same issues and the culprit was the cheap chinese bulbs.
Have you used cheaper after market bulbs? I noticed in pics your using the Sylvania bulb. I encountered the same issue with my 2001. As long as I used the regular bulbs I was ok. When I went to change the bulb with some so called high end bulb that I purchased from ebay, I melted the connector and damaged the lamp assembly too. The cheap Chinese bulb (blue light bulb), said it was the same wattage as the Sylvania I replaced. Well it wasn't. The dealer said they were getting trucks in quite often with the same issues and the culprit was the cheap chinese bulbs.
Cause: Any resistance in the bulb-to-harness connection will generate heat. As the connection heats up, resistance can increase. The result is a melted connection.
Solution: The bulb to harness connection needs to be totally clean so that there is a solid electrical connection.
I have managed to prove this to myself a time or two....
Lou Braun
Solution: The bulb to harness connection needs to be totally clean so that there is a solid electrical connection.
I have managed to prove this to myself a time or two....
Lou Braun
I ended up buying a cheap headlamp assembly at Sorta Fit just in case it goes bad again instantly. YouTube helped, although that bottom tab is a bitch.
How To Install Replace Headlight and Bulb 99-04 Ford Super Duty F250 F350 1AAuto.com - YouTube
Posting Guru
Joined: Jan 2004
Posts: 1,736
Likes: 1
From: Monroe, MI
Greenlawn,
The Sylvania is a good bulb. That's all I use now. I was just wondering if maybe you had used a cheaper bulb prior that may have caused some damage to the harness near the connector. It's obvious the resistance increased tremndously to cause all that heat.
When my issue happened the dealer cut the bad connector off, butt spliced a new one and I never had an issue again.
The Sylvania is a good bulb. That's all I use now. I was just wondering if maybe you had used a cheaper bulb prior that may have caused some damage to the harness near the connector. It's obvious the resistance increased tremndously to cause all that heat.
When my issue happened the dealer cut the bad connector off, butt spliced a new one and I never had an issue again.
Thread
Thread Starter
Forum
Replies
Last Post
Evan_P
1987 - 1996 F150 & Larger F-Series Trucks
62
Apr 12, 2019 03:10 AM
Squirrel13
Excursion - King of SUVs
3
Sep 27, 2018 10:11 AM
shanes66charger
Ford Truck Parts for Sale
3
Apr 4, 2016 01:20 PM
dixie460
1987 - 1996 F150 & Larger F-Series Trucks
35
Jun 16, 2015 06:00 AM
