The 1947 - Present Chevrolet & GMC Truck Message Board Network







Register or Log In To remove these advertisements.

Go Back   The 1947 - Present Chevrolet & GMC Truck Message Board Network > Welcome and Discussion > General Discussion

Web 67-72chevytrucks.com


Reply
 
Thread Tools Display Modes
Old 06-16-2019, 05:58 PM   #1
bradleyheathhays
Registered User
 
Join Date: Aug 2017
Location: Lexington, Ky
Posts: 20
Melted electrical connection...what to do?

So I put a headlight wiring kit from LMC Truck on my '96 Cherokee that circumvents the normal wiring and runs the headlights directly off the battery by way of a relay.
The kit runs the lights at 55/100 (low, hi) watts instead of the original 55/60. One reason I did this was because the light output was terrible, and the other was because for some unknown reason the headlights would shut off after being on hi for a bit. Never did this on low. I've had the new wiring kit on for a few years now and it seems to have solved the issue.

The problem I'm having now though is that this new harness is melting at one of the connections...

The melted connection is on the right side towards the bottom.

You can see only one of the wires is overheating while the other seems to be ok. I'm guessing the hot one is used by the high beams.

What could be causing this? Could it be related to why the high beams used to shut off before I replaced the wiring harness? A while back I asked about the shutting off issue on a number of Jeep boards but nobody had heard of this particular problem before.
Attached Images
 

Last edited by LockDoc; 06-16-2019 at 10:13 PM. Reason: Resize picture
bradleyheathhays is offline   Reply With Quote
Old 06-16-2019, 09:06 PM   #2
Sheepdip
Registered User
 
Sheepdip's Avatar
 
Join Date: Nov 2018
Location: Waterford California
Posts: 232
Re: Melted electrical connection...what to do?

A loose connection will generate heat.
Sheepdip is offline   Reply With Quote
Old 06-16-2019, 09:23 PM   #3
Warrens69GMC
Registered User
 
Warrens69GMC's Avatar
 
Join Date: Jan 2003
Location: Safford,AZ
Posts: 1,822
Re: Melted electrical connection...what to do?

After your headlights turned themselves off, did you replace the bulbs/headlights?
__________________
1969 307, t350
1950 Chevy Wagon
Warrens69GMC is offline   Reply With Quote
Old 06-16-2019, 10:48 PM   #4
1976gmc20
Registered User
 
Join Date: May 2015
Location: Montana
Posts: 463
Re: Melted electrical connection...what to do?

So you're running the lights directly off the battery with no fuse ???
__________________
Current/past Chevy/GMC trucks:
1958 Chevy C-60; 1965 GMC C-50; 1965 Chevy C-10
1971 Chevy K-10; 1973 Chevy K-20; 1976 GMC C-20
1977 Chevy C-10 Suburban; 1980 Chevy K-10
1989 Chevy K1500; 1991 GMC V1500 Suburban
1976gmc20 is offline   Reply With Quote
Old 06-17-2019, 12:57 AM   #5
bradleyheathhays
Registered User
 
Join Date: Aug 2017
Location: Lexington, Ky
Posts: 20
Re: Melted electrical connection...what to do?

Warren, I don't think I replaced the headlights during the previous problem. They were normal 55/60 headlights. I replaced the bulbs with 55/100 when I put this new kit in.

Yeah...no fuse...not a good idea. I understand that now. Seems like the harness kit would have come with a fuse built in.
bradleyheathhays is offline   Reply With Quote
Old 06-17-2019, 07:44 AM   #6
special-K
Special Order
 
special-K's Avatar
 
Join Date: Nov 2004
Location: Mt.Airy,MD
Posts: 69,261
Re: Melted electrical connection...what to do?

That should have been a pretty good connection. Should use dielectric grease there. I would check and improve any grounds you see... after you get that circuit fused.
__________________
"BUILDING A BETTER WAY TO SERVE THE USA"......67/72......"The New Breed" GMC

'67 C1500 Wideside Super Custom SWB: 327/M22/3.42 posi..........'The 67' (project)
'72 K2500 Wideside Sierra Custom Camper: 350/TH350/4.10 Power-Lok...'The 72' (rolling)
Tim

"Don't call me a redneck. I'm a rough cut country gentleman"

R.I.P. ~ East Side Low Life ~ El Jay ~ 72BLUZ ~ Fasteddie69 ~ Ron586
special-K is offline   Reply With Quote
Reply

Bookmarks

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -4. The time now is 01:18 PM.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.
Copyright 1997-2013 67-72chevytrucks.com