Low beam connector melted?

[get_over_it]

OK so I'm back again this time its my headlights, the low beam! I sorta started this in another thread some one was asking about bulb info, and I didn't want to thread jack OP so I'm posting a new thread.

I have Eurolite installed in my high and low beams, the high beams are fine (at least for now) but a couple of days ago I noticed both my lights were out so I checked and it seemed that the connections were loose as I pushed them together and they lit back up. Now to the other night, the driver side light out again, so I checked the connection and the light lit up again but a couple of minutes later it was out. I opened the hood and pulled the dust cap and the connector was smoking so I disconnected and turned off and let cool.

Yesterday it was suggested that the bulbs may be higher than our allowed 55w, it is printed on the bulb and on the product description page for the manufacturers web site/ The Distributors web site "9006 12v 55w. So this is not an issue of over wattage.

It was also suggested that since the Eurolite meet OEM specs that I should go after the company to fix my headlights, so I was looking around their web site and found a page dedicated to "Tech Tips" for EUROLITE! The page is located @http://www.toucanindustries.com/clientuploads/techtips/TIPS/BULBS.pdf
There is a couple of things that I noticed, does it sound like that they are aware of this issue so with out saying it out right they are making this their disclaimer? I don't have anything spliced into the lighting harness so it's not drawing any extra currant then normal, I do have an aftermarket stereo, amp and subs but how does that affect the headlights?

Any idea as to what the cause for this is? I have the dust cap covers on so its not likely moisture is getting in there. I do have pictures of the Burnt connector/light bulb if needed.

But either way I need to replace this asap as I don't need to get a ticket for driving with a burnt out headlight. GM list this part (#6) which I assume is the connector only or is this a harness? link to part here http://www.gmpartsdistributor.com/partlocator/index.cfm?action=getJointLocator&siteid=213761&chapter=&Sectionids=0,2295&groupid=2296&subgroupid=4170&componentid=0&make=6&model=TrailBlazer&year=2003&graphicID=GN02045&callout=6&catalogid=2&displayCatalogid=0

Again Thanks in advance,
Jay

[The Roadie]

There are heavier-duty aftermarket connector harnesses you can buy. Don't just replace it with another GM underdesigned unit. Small amounts of contact resistance from oxidation are the root cause, and many folks get relief by using some bulb grease in the socket to exclude air from the contact area.

[get_over_it]

Thanks, I did not know about dielectric grease. So I called GM and finally after 6 hours (I was at work anyways) and two call backs confirming the part needed (socket) they quoted $44 and it would have to be ordered, yes against your recomondation of a better quality harness, but I didn't get it. Instead I went to Collins who deals mostly with AC delco and got part #S523 it has 18AWG wiring apposed to the 20-22 stock GM uses and also has the silicone weather guard and it was only $15!

So I picked up one some dielectric grease and new headlights GE Nighthawk Platinum since the other was the source of the melting. I got home removed the headlight and spliced in the new connector, reassembled and tada!

But I started the party too soon, I went to replace the passenger side headlight only to notice that that one had melted the connector too, but did not fail I guess I should have checked first. So off today to get socket #2!

Thanks again!