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Melted Headlight Connector

Discussion in 'Generation 1 Prius Discussion' started by jamesprius, Oct 15, 2024 at 1:35 AM.

  1. jamesprius

    jamesprius Member

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    After removing the left headlight assembly and disconnected what appears to be the low beam, noticed the plastic connector is melted / burned. The other connectors seem fine. Not sure what would cause it? I think the headlight is still working though.

    How do you replace this? Need to solder a new one on?
     

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    #1 jamesprius, Oct 15, 2024 at 1:35 AM
  2. Tombukt2

    Tombukt2 Senior Member

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    Put LED. Bulbs in no mo heat. No melt . My Corollas same LED and done re aim..
     
    #2 Tombukt2, Oct 15, 2024 at 9:21 AM
  3. rjparker

    rjparker Tu Humilde Sirviente

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    Bad connections heat up the connectors and burn out bulbs faster.

    You can get a new connector and short wiring pigtail at an auto parts store or Amazon. Usually they come with crimp connectors. You cut yours out and put the new one in.

    These are for H4/9003 bulbs I have used on gen2s. Get good ceramic connectors.

    IMG_6426.jpeg

    IMG_6425.jpeg
    IMG_6427.jpeg
     
    #3 rjparker, Oct 15, 2024 at 9:32 AM
    Last edited: Oct 15, 2024 at 10:56 AM
  4. Trombone

    Trombone Member

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    #4 Trombone, Oct 15, 2024 at 1:14 PM
  5. jamesprius

    jamesprius Member

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    Thanks what does the other end for look like for those?

    I found these (see attached) with tabs. I guess you just loop the wire from the otherwise and wrap it a few times, without having to purchase the crimp connectors??

    This video showed stripping, using crimp connector, wrapping with heat shrink and then wrapping w/ electrical tape. Didn't not realize there was so many steps.

     

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    #5 jamesprius, Oct 15, 2024 at 2:13 PM
    Last edited: Oct 15, 2024 at 5:55 PM
  6. jamesprius

    jamesprius Member

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    Anyone try this before? Just pushing the wires out of the replacement connector, do the same on the old one and just insert into the new one without any cutting. Not sure if possible on the H4.

     
    #6 jamesprius, Oct 15, 2024 at 2:41 PM
  7. Tombukt2

    Tombukt2 Senior Member

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    Yeah I have those on my bike those are the way to go if you're keeping halogen H4 they're like old outlets from long ago
     
    #7 Tombukt2, Oct 15, 2024 at 3:07 PM
  8. Tombukt2

    Tombukt2 Senior Member

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    The ones with the push pins on the back of the spades they're made to convert from h8 and h11 and all that business and things similar. The point is though you're old connector is melted so even the brass pins or whatever they are in the connectors the metal has been heated when you pull it out you'll notice it may have lost its temper or whatever you call it doesn't hold well to the new connection usually better to cut it off and use a Scotch lock connector or similar type of connector and you're good to go for longer than the car is going to last you usually.
     
    #8 Tombukt2, Oct 15, 2024 at 3:08 PM
  9. rjparker

    rjparker Tu Humilde Sirviente

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    The existing harness is big and complicated. Just cut out a few inches of the existing connector and wire and crimp. Crimp is not soldering but the crimp connector could be a heat shrink butt connector with built in solder. If this seems too difficult have a shop do it.

    Otherwise you are risking continued problems.
     
    #9 rjparker, Oct 15, 2024 at 6:43 PM
    Last edited: Oct 15, 2024 at 6:48 PM
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