Melted headlight connector — what causes it and how to fix it the right way What causes a headlight connector to melt? The #1 cause of melted headlight connectors is too small a wire gauge from the factory It’s not uncommon to see a 20-gauge wire harness for headlights. With the headlights connectors packed into tight places with little airflow, the combination a wire gauge that’s too small creating heat from resistance, lack of airflow, and heat from the headlight bulb, you wind up with a melted connector. The melted … Read More
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