Why Does My Headlight Plug Keep Melting?

Among all the other reasons, improper replacement parts are the main cause behind this melting plug issue. For instance, the OE wire gauge of your car might be too small or thin to withstand the power produced by the battery. And as it is made of plastic, it can end up being burnt along with the headlight plug.

Reasons For Why Does My Headlight Plug Keep Melting

Sometimes when our headlights stop working, we think that this might be a routine headlight replacement. But after unplugging the bulb, we realize that the collector is melted. 

This situation is quite common for the car owner, no matter what brand or model of the car they have. And most of the time, the OE wire gauge is the one to blame here. Because sometimes that little wire gauge might be too small to deal with the current load of the headlight bulbs.

Just like this one, an inappropriate headlight bulb, or a loose or bad connection can also cause this issue. To know more about why my headlight plug keeps melting, keep digging further.

Loose Connection

You can face quite similar consequences when there is a loose terminal connection. Because the loose connection might lead to resistance in the circuit, and then end up causing overheating. 

And if your headlight bulb is too upgraded for your car, it can cause overheating as well. In most cases, the headlight plug is made of plastic to ensure proper insulation to the internal connections. And that is why overheating is a serious issue there.

But that’s not all. There are plenty of other reasons why the headlight plug keeps melting. So let’s talk about them in detail.

OE Wire Gauge

Most of the OE wire gauges are 20 gauges. And for handling the current drawn by the headlight bulbs, these OE wire gauges are too small or thin. Also, you might find aluminum in some parts here instead of copper.

As a result, these OE wire gauges are not enough durable as they cannot withstand high temperatures. So when overheating occurs, it tends to melt down and stops functioning properly. Thus, for long-term use, this is not an ideal choice for you.

High Voltage Bulb

It is only normal that we would want to have a headlight bulb that is more powerful and brighter. So when you replace the old default headlight bulb with a new one, you would want a bulb of higher voltage. Usually, you will not have any issue with it as long as it goes perfectly with your car model.

But sometimes, the high voltage bulb might become too upgraded for the system to work with. And sometimes, overheating might take place when you turn the light on. This overheating can melt down the socket while damaging the wiring insulation and softening them. 

Bad Electric Contact

If the electric connections are not done properly, you might have poor electric contact. So there remains a high chance of overheating. It might distribute low intense or improper charges throughout the system. And that can lead to burning the socket or plugs and hence, damage the internal wires.

You can see these types of problems in cold weather where humidity largely affects the power supply system. And therefore, it damages the sockets with corrosion.

Replacing with DOT Headlamps

Usually, DOT headlamps are brighter options for a replacement of headlight lamps. But the problem is, it takes more current to work properly. And that is why you have to change some arrangements in the internal current supply. 

The particular car you have might not be suitable for the requirement of the DOT headlamps. So if you do not change the internal current supply system and still change the bulb, the electric charge might not reach the bulb properly. And that continuous emission of the charge might heat the wiring as well as the socket.

Loose Connection

A loose connection in your headlight bulb might lead to resistance in the flow of electricity. In this particular case, you might notice a blinking issue in your headlights. And if you do so, immediately take the necessary steps to tackle the situation. Otherwise, you might end up having a more critical situation like burnt plugs or damaged wiring.

Low-quality Headlight Bulbs

Low-quality headlight bulbs might not be powerful enough to withstand the electricity they would get from the battery. So if you replace your old headlight bulb with a low-quality one, it might be fused all of a sudden. 

Also, there might be some sort of sparking issue that can cause the heating issue. And therefore, the headlight plug might get damaged.

Ground Connection Wire

If your car ever has any short circuit or sparks in it, it is the ground connection wire that saves the day for you. It just passes the electricity to the ground. But if you do not have a properly working ground connection wire, that spark might remain in the system and hence cause overheating.

How to Detect Faulty Headlight Plug?

Some signs will indicate that you have a faulty headlight plug. And one of the most common signs is the burning smell. Both the wirings and the socket might get burnt and causes that smell. 

Although that might be a little insignificant for you to locate the cause. But if you come out at the front of your car, you might be able to detect the exact origin of the smell. 

And as we have mentioned before, blinking of the headlight might be one of the consequences of a burnt headlight plug. Besides, the intensity of the light might get reduced a little bit. 

How Do You Check a Headlight Connector?

To check the condition of the headlight connector, go through the following steps:

Step 1: Make sure that the headlight connector plug is disconnected.

Step 2: Now turn the headlights on.

Step 3: At this point, connect the test headlight/light to the connector terminal and see if that is functioning properly or not.

How to Fix Melted Headlight Plug?

If the headlight plug is melted, there is no way you can fix that. The only thing you can do is remove and then replace it with a new one. You can find this replacement part which is called a pigtail in any automotive store.

Frequently Asked Questions

How much does it cost to replace the headlight plug?

If you change the headlight plug by yourself, it would cost you from $70 to $120. But for professional assistance, you will have to pay extra.

How long should headlights last?

Usually, a headlight bulb of standard quality will last up to 500 to 1000 hours. However, the range is quite large. But there are lots of factors behind it. And you might even find headlights that can last even up to 30,000 hours. Generally overtime the headlights might start to flicker or completely gone and needs to be changed at this moment.

Conclusion

To prevent the headlight plug from melting, make sure that you are using standard-quality wiring and replacement parts. Also, you will have to consider the overheating issue as well. And now that you know why my headlight plug keeps melting, you will be able to locate the problem and find a solution more easily.