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Headlight connector scorched - where to get replacement conncector?

25K views 7 replies 7 participants last post by  IrishMan68  
#1 ·
2012 Fiat 500L. Went to replace the right headlamp bulb, but found the connector to be scorched/burned. Local Fiat dealer says the connector is not sold separately, so I have to buy a $700 front wiring harness. Questions:
1) Does anybody know where I can just buy the right connector? I can splice the wires no problem.
2) Fiat dealer parts department says this may have been caused by using aftermarket bulb, which was the case. Does anybody know about this being an issue?

Thanks,
jdr
 
#3 ·
NAPA sells connectors, as does O'Reilly, Advance Auto, Carquest, etc.
The issue is the path to ground. The wiring is very lightweight, not robust like the wires on my 1966 Chevy C-10.
My issue was the LF headlamp. Working swing shift, I get off @ 11:00 pm and could tell that only 1 headlamp was on. Pop the hood, remove the housing cap and reach in and wiggle the wires. Voila! 2 headlamps.
Rallylights.com sell a ultra high temperature connector, a 9006CF female socket.
I wired in 2 different connectors and one burned up in 3 weeks. The second one is still working fine. I use the standard 60/55w bulbs, and the dealer cannot blame an aftermarket bulb as it is a consumable, just like brake pads and air filters. They may not like you bypassing them for ALL your parts. It's your money.
 
#4 ·
I have the same issue as @Soarboy4442. I bought the "Standard Motor Products HP3960 handypack Headlight Connector" that all of the automotive sites said "fit" my 2015 Fiat 500 Pop", However, it only has 2 wires and my connector has 3.

Attached are the side and top images of the scorched connector and a stock image of the part that's supposed to fit.

Any suggestions on how to splice the 3 into 2 (or any solution, for that matter)?
108204

108205

108206
 
#6 ·
I have the same problem.
And I am curious which part id is the correct one: 9005 or 9006? Images I see on web search results both looks same to me. Is it safe to use either one?

I have the same issue as @Soarboy4442. I bought the "Standard Motor Products HP3960 handypack Headlight Connector" that all of the automotive sites said "fit" my 2015 Fiat 500 Pop", However, it only has 2 wires and my connector has 3.

Attached are the side and top images of the scorched connector and a stock image of the part that's supposed to fit.

Any suggestions on how to splice the 3 into 2 (or any solution, for that matter)?
View attachment 108204
View attachment 108205
View attachment 108206
 
#5 ·
Follow the ground path, from the bulb to the frame, checking it carefully, and clean every connection in it. impedance there can melt connectors or foul wiring by melting it’s insulation into the strands. Look for fouled crimps, any stiffer hardened areas of wiring that may (or may not) appear to have been overheated. Replace any other wires or components that also overheated.