Was changing my headlight bulbs this evening and noticed that the ground connection of both connectors is melted quite badly. I’m assuming this is a fire hazard to continue using the headlights?
Is it as simple as just changing the plugs for some new ones? I’m also guessing I’ll need to trace the earth connections and check them for excessive resistance?
Hoping someone with a bit more electrical knowledge than myself can chime in with some advice.
My connectors ended up corroded after nearly 30 years. I just cut them off, and wired in Ring Ceramic H4 connectors. You know, they’re making them in ceramic for a reason.
The only time I’ve had a problem with overheated/melting light fittings is when after-market “uprated” bulbs had been fitted.
If you decide to fit new plugs, such as the ceramic ones shown above, the point of most resistance is then likely to be the wiring joints so ideally they need to be fitted by someone who knows what they’re doing. Crimped joints are probably best; I like to crimp for strength and then solder to ensure minimum resistance.
I wouldn’t think that a poor earth would cause this, it’s probably just old age corrosion at the terminals in the plug itself. BTW, if an earth wire breaks it’s not a fire hazard - a “live” wire touching the bodywork possibly is - but the “live” circuit should be protected by the relevant fuse anyway - it should blow; that’s why we have fuses.