harness getting hot

[delkampg]

imma put a post up on this cause ive been flooding cyberpoet's inbox...sorry

cyberpoet has walked me threw fixing my headlights. the previous owner had car headlights in there and it melted the sockets and fried a female connector. i tried to replace the connector but couldnt find one small enough so i bypassed the harness and coneected the one wire with a snap connector and then there was light

while giveing the lights a once over they went out so i jiggled things around and tracked down the loose wire to the black harness comeing from the starter switch/engine stop switch. it was also getting fairly hot, i smelt the harness and it smells like it might have been burning, or at one time may have been burnt. im not sure exactly which wire was causeing the problem but ive spent some time with the wireing diagram and there is only one wire that leads to the headlight harness, which is marked in red.

the bulbs that are in there are 60/55

here is the wiring diagram the one wire is marked in red http://i290.photobucket.com/albums/l.../98_wiring.jpg

[Londob5]

OK...But you didn't ask a question. Not that I could solve your problem anyway. However, are you looking for a new harness, or looking to track down the wiring?

[delkampg]

o sorry i thought the question was obvious, the right bulbs are in there so why would the harness get hot? especially in a harness that has very little to do with the lights.

[96gsxohio]

I'm having problems with my wiring harness too...well...basically the headlight socket. A few months back my headlight wire socket melted on the back 3 prongs of the bulb. I had to go on a poker run that day and had to make a quick fix, so I went to AutoZone and bought a 2 pack of headlight wiring harnesses. Hooked it up and the headlight worked fine!

About 6 hours later, I smelled melting plastic and looking at the harness...it had melted on the 3 prongs again! I changed the harness out to the other one the day later and it worked for about 4 weeks...then same thing

Anyone know what would cause the wiring harness for the headlight to melt on the prongs of the headlight like that? Could it be a bare wire grounding out somewhere? Any help is much appreciated!

Thanks,
PJ

[kevin2502000]

Too big of wattage bulb?

[Kreylyn]

I'm having problems with my wiring harness too...well...basically the headlight socket. A few months back my headlight wire socket melted on the back 3 prongs of the bulb. I had to go on a poker run that day and had to make a quick fix, so I went to AutoZone and bought a 2 pack of headlight wiring harnesses. Hooked it up and the headlight worked fine!

About 6 hours later, I smelled melting plastic and looking at the harness...it had melted on the 3 prongs again! I changed the harness out to the other one the day later and it worked for about 4 weeks...then same thing

Anyone know what would cause the wiring harness for the headlight to melt on the prongs of the headlight like that? Could it be a bare wire grounding out somewhere? Any help is much appreciated!

Thanks,
PJ

Poor connection/ground somewhere that is causing an increase in resistance (resistance = heat) in the ciruit, and the harness is the weakest link.

Trace/clean all connections.

Krey

[96gsxohio]

I will check the bulb and connections as well. Thanks for the input.

Was hoping others had the same exact problem and could trace it to a common cause, but this is definitely a great start!

[96gsxohio]

Ok, the bulb is "Super Spots H4 12V 60/55W P43T" and should be fine. The wire harness on the other hand is just not working out. Anyone know the nomenclature of have a schematic that I can order a new one from?

I still have to get a multimeter to check voltage to check the wires. Pictures below (sorry they are darker, but it's from my phone). Hopefully someone will recognize they had the same issue and can help point to a certain area.