Headlight connector keeps melting? - Chevy TrailBlazer, TrailBlazer SS and GMC Envoy Forum



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  #1  
Old 02-08-2010, 08:07 PM
rarnone rarnone is offline
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2002 Chevy TrailBlazer LTZ
Indigo Blue Metallic 4.2L I6 4X4
Join Date: Feb 2010
Location: St. Paul, MN
Posts: 3
Headlight connector keeps melting?

I have a 2002 trailBlazer LTZ, the connectors for the low beams keep melting. I have replaced the left one at least twice and have just replaced the right one. I replace the lamps each time with Wagner 9006 lamps. The original connector wiring is only 20 gauge, the new (after market connectors are 14 gauge). It seems like the bulbs are drawing to much current to actually melt the plastic of the connector? Could it be that the grounds are bad or poor quality replacement lamps or just the wires of the original connectors are just not heavy enough to carry the current? I noticed another incident of this posted on "MyCarStats.com". Is this an issue that Chevy is aware of I have not seen any recalls for this. I know there was an issue and recall on the tail light assemblies, which I have had done.
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  #2  
Old 02-08-2010, 08:50 PM
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the roadie the roadie is offline
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2004 GMC Envoy SLT "Roadiemobile"
Extreme Offroad Pewter 4.2L I6 4X4
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A bad ground would generate heat at the ground connection, and not affect the bulb socket. If anything, heat generated at the ground would REDUCE the potential heat that could be generated at the socket. Best suggestion if you're already using aftermarket harnesses is to add bulb grease to the socket to try to reduce any oxidation in there - oxidation increases the resistance of the connection, and that's what generates heat. Increased tightness of the socket reduces resistance, if you can pinch it together before inserting the lamp.
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  #3  
Old 02-15-2010, 08:44 PM
jasonkrons jasonkrons is offline
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2002 GMC Envoy SLT
Pewter Metallic 4.2L I6 2WD
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Location: Charleston, SC
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Front Right Headlight

I have replaced my front right headlight month after month. Have you figured anything out. I did notice that the plastic connector seems to be a bit melted as well. Additionally, my right rear running light and brake light burns out just about as regularly. Please let me know if you figure anything out. Thanks.
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  #4  
Old 02-16-2010, 09:58 PM
rarnone rarnone is offline
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2002 Chevy TrailBlazer LTZ
Indigo Blue Metallic 4.2L I6 4X4
Join Date: Feb 2010
Location: St. Paul, MN
Posts: 3
Headlight connectors

I suspect the issue is with the quality of the lamps. I seem to have more problems with Wagner 9006's. As for the connectors, I have replaced the left one twice; the first time with an OEM connector, the second time was an after market connector with heavier gauge wire and a different material of the connetor itself. I just replaced the R/h headlamp and connector. The original factory connector, made of a hard white plastic was also melted, so I replaced it with the aftermarket connector ( just splice in and I reccommend either good quality sealed connectors or apply heat shrink over "butt" splices) the new aftermarket connectors seem to be working better. This is the reason I joined this forum to see how many people were having this same issue with head lamps and connectors, it seems rather prevelant. As for the rear light, there was a recall or campaign to replace the whole tail light assembly. I have had the assemblies replaced on my 2002 TB and have not had a single issue since. I did have some problems with the tail lights before the replacement. I hope this helps.
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  #5  
Old 02-16-2010, 10:09 PM
mikelee mikelee is offline
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2002 Chevy TrailBlazer LS
Indigo Blue Metallic 4.2L I6 4X4
Join Date: Jul 2007
Location: Fargo ND
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I have been battling this issue for a couple of years now. I have changed to aftermarket connectors as well, and i also have burnt a couple of those up too. They did seem to last longer though. About six months ago i changed to sylvania silverstars and have good luck with them. Havent had any more burnt conectors yet... knock on wood
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  #6  
Old 09-30-2013, 02:16 PM
Cjabbouri Cjabbouri is offline
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2004 GMC Envoy SLE
Fire Red 4.2L I6 4X4
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2002 Trailblazer Headlight melting

I am having the same issue dose anyone have a fix.
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  #7  
Old 10-04-2013, 09:43 PM
joshusmckee78 joshusmckee78 is offline
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2004 GMC Envoy SLT XL
Carbon Metallic 4.2L I6 4X4
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Arrow 2004 Envoy heas light sockets melting

I found ceramic headlight sockets with 14 ga wire.I put them in a year agow and have not had a proyblem sense.
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  #8  
Old 04-01-2014, 01:41 PM
Red-Horse-Ed Red-Horse-Ed is offline
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2005 Chevy TrailBlazer LS
Summit White 5.3L V8 4X4
Join Date: Apr 2014
Location: Valley Forge, PA
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2005 head lamp connetor melting

I have the same issue with the lamp socket (which looks like a connector) melting. The fix the dealer gave me was to purchase a whole new headlamp assembly. $200 for non-GM.
Could it be the relay going bad and putting current into the bulb constantly?
Usually when the relay goes bad both head lights go out.
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