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View Full Version : Melting wiring harness to headlights



jason2187
05-23-2015, 05:27 PM
What would cause the plug on the wiring harness to the headlight switch to melt?

4.3LXJ
05-23-2015, 05:42 PM
Could be a couple of things. Are you running stock bulbs?

jason2187
05-23-2015, 06:35 PM
They are stock headlights.

4.3LXJ
05-23-2015, 07:25 PM
The only reason I could think of then is that there was a bad connection there and the arcing caused enough heat to melt plastic.

jason2187
05-24-2015, 12:24 AM
Can I just cut one of those wiring harnesses out of a jeep in a salvage yard or do they sell like a piggy back? Because I'm sure jeep will gladly sell me one for some out ragous price. I am like most others and am on a budget so I wanna do it for the best way possible on a budget.

OldFaurt
05-24-2015, 07:38 AM
What would cause the plug on the wiring harness to the headlight switch to melt?

In my case, The 10-pin connector under the Air box, was the problem...
7668
This connector is susceptible to moisture and therefore, corrosion.
7669
As is it's mating connector...

Try cleaning the connector and using Dielectric grease to keep moisture out!

4.3LXJ
05-24-2015, 09:01 AM
Can I just cut one of those wiring harnesses out of a jeep in a salvage yard or do they sell like a piggy back? Because I'm sure jeep will gladly sell me one for some out ragous price. I am like most others and am on a budget so I wanna do it for the best way possible on a budget.

Yes, you could splice it it. Make sure you make good connections

OldFaurt
05-24-2015, 10:54 AM
What would cause the plug on the wiring harness to the headlight switch to melt?

This, or the one for your year should work out...
This is the one for a 1992 XJ (http://www.rockauto.com/catalog/raframecatalog.php?carcode=1180112&parttype=2572)
you could just splice this one in...

jason2187
05-24-2015, 11:59 AM
Thanks. I looked at a lot of other places and couldn't find one I was ready to go to the salvage yard and cut one out.

4.3LXJ
05-24-2015, 12:55 PM
You can also buy those plug kits on ebay