Headlights problem, again its burnt!
Thread Starter
Racer
Joined: May 2006
Posts: 415
Likes: 0
From: Dallas TX
Headlights problem, again its burnt!
First some background, a couple months ago my low beams went out, turns out the relay on that switch burnt so I replaced it and even though were it plugs into was slightly burnt, no other damage to the wiring so I was back in business. Well, the low beams went out again. Once again pulled off the relay, and this is what I see. I tried this relay in place of the one on the highbeams and it works fine which leads me to believe something is wrong with the box. Is it possible to cut this old one off and splice the corresponding wires to one from an auto store? How do I fix this?
Race Director
Joined: Apr 2002
Posts: 11,485
Likes: 1
From: Far side of the Moon
CI 4-5-6-7-8 Veteran
St. Jude '03-'04-'05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15-16-'17
I think you have something to be concerned about going on. Might I suggest you have someone experienced check out the wiring and low beam circuit.
You asked about replacing the relay. Yes, that can be done if you know the pin out for the existing relay compared to a replacement.
But something is causing the circuit to heat up enough to melt / burn the connectors. From the looks of things you got lucky in that the melting plastic broke the circuit and simply your lights went out, otherwise you'd have a fire to deal with.
One also has to wonder why a fuse somewhere didn't blow long before that connector even got warm, much less hot enough to burn plastic.
You should have someone knowledgeable check it out. I think you're looking at a symptom, not the root cause.
Good luck.
You asked about replacing the relay. Yes, that can be done if you know the pin out for the existing relay compared to a replacement.
But something is causing the circuit to heat up enough to melt / burn the connectors. From the looks of things you got lucky in that the melting plastic broke the circuit and simply your lights went out, otherwise you'd have a fire to deal with.
One also has to wonder why a fuse somewhere didn't blow long before that connector even got warm, much less hot enough to burn plastic.
You should have someone knowledgeable check it out. I think you're looking at a symptom, not the root cause.
Good luck.
Burning Brakes
Joined: Aug 2006
Posts: 1,217
Likes: 5
From: Stark County Ohio
For a good permanent trouble free wire splice -
Solder the wires using shrink tubing instead of tape. The “butt” (crimp) connector in the photo is not as good as soldering the joint.
C5 Electrical Connectors -
http://forums.corvetteforum.com/show....php?t=1887587
http://www.picowiring.com/
http://www.picowiring.com/pdf/PICO-27-28-29.pdf
http://www.casperselectronics.com/
www.delcity.net
Instructor
Joined: Aug 2007
Posts: 158
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From: DFW Big State Of Texas
Le Mans Master
Joined: Mar 2002
Posts: 8,466
Likes: 51
St. Jude Donor '17
The wire behind the box is bare copper
You can see it in the pics at the same location of the burn
You had tape or something covering this right?
You can see it in the pics at the same location of the burn
You had tape or something covering this right?
Last edited by Got uid0; Dec 19, 2007 at 06:00 PM.
Instructor
Joined: Aug 2007
Posts: 158
Likes: 0
From: DFW Big State Of Texas
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Thread Starter
Racer
Joined: May 2006
Posts: 415
Likes: 0
From: Dallas TX
Actually in the second pic you can see how it burnt and I pulled it out from the bottom it was just resting inside there.
