Melted Headlight Connectors on V40!

motty · Mar 20th, 2009, 14:51

Hi Guys,

Having a real headache with my V40's headlights. Everytime I start up, one of the headlights doesnt come on. I normally have to fiddle with the veadlight level to get it to come on.

On closer inspection found that both Headlight connectors look melted/brittle hence the poor contact. one of the wires on each side has come away completely, leaving a bare spade connector that plugs onto the bulb.

How can I fix this? Any idea's? Will it be an expensive job?

Thanks,

Alan.

birdwood · Mar 20th, 2009, 21:43

i had just the same problem with my v 40 it took ages to find it too

what i did to sort it was to buy two new halogen bulb connectors from a decent spares shop .or factors (scrap yard ones will probably be a bit nacked)
try a auto electricians
The two i bought came with about 4 inches of wire to each of the terminals the colour coding probably will not match but no probs
then cut the old sockets off one wire at a time to ensure that you reconect the new socket in the correct wiring pattern to join the wires i used high amperage choc blocks due to the extreme heat and insulated them with good quality tape i even considered using small household electrical junction boxes as they are made of hard bakelite plastic its an easy repair a couple of hours if that and no more than a tenner

myatt1972 · Mar 20th, 2009, 21:52

Have you got uprated bulbs fitted? If you have they will draw more current which could contribute to the melting.
Keith...

scottishvolvo · Mar 20th, 2009, 22:15

Drivers side one on mine is the same with normal bulbs. I have the connector but haven't got round to fitting it yet.

myatt1972 · Mar 20th, 2009, 22:17

Im going to check mine tomorrow then, sounds like a common problem.
Keith...

stevo48 · Mar 20th, 2009, 23:38

Go to any good auto shop and ask for a pair of H4 connectors they come complete with brass spade connectors as opposed to mild steel connectors so you get better conductivity as the mild steel connectors tend to corrode causing high resistance.

ChrisRidett · Mar 23rd, 2009, 11:20

Same here, Drivers side connector bust and cables cooked. Once replacements arrive from ebay will look at crimping them on. I'm also missing the circlular cover plate from the back - I wonder if that led to the corrosion/ melting.

motty · Mar 23rd, 2009, 15:41

Thanks for the replies chaps.

Purchased some H4 connectors off of ebay and some 15amp connection blocks from Halfords. Hopefully this will do the job.

Alan.

motty · Mar 24th, 2009, 16:06

Just had a quick look at what I need to do.

I have to say there isn't much existing wire to work with (or room).

Hoping I can strip back shielding on exisiting wire Ok and connect a connector block to it.

Alan.

adamsky01 · Mar 25th, 2009, 02:07

there is a service kit for this speack to rufe it aint dear i think thats the part no 30652035 but not sure ask rufe and tell him ur reg

Mar 20th, 2009, 14:51	#1
motty New Member Last Online: Apr 2nd, 2009 08:53 Join Date: Feb 2007 Location: pirbright	Melted Headlight Connectors on V40! Hi Guys, Having a real headache with my V40's headlights. Everytime I start up, one of the headlights doesnt come on. I normally have to fiddle with the veadlight level to get it to come on. On closer inspection found that both Headlight connectors look melted/brittle hence the poor contact. one of the wires on each side has come away completely, leaving a bare spade connector that plugs onto the bulb. How can I fix this? Any idea's? Will it be an expensive job? Thanks, Alan.

Mar 20th, 2009, 21:43	#2
birdwood New Member Last Online: Oct 18th, 2009 01:02 Join Date: Sep 2008 Location: milton keynes	molten headlight terminals i had just the same problem with my v 40 it took ages to find it too what i did to sort it was to buy two new halogen bulb connectors from a decent spares shop .or factors (scrap yard ones will probably be a bit nacked) try a auto electricians The two i bought came with about 4 inches of wire to each of the terminals the colour coding probably will not match but no probs then cut the old sockets off one wire at a time to ensure that you reconect the new socket in the correct wiring pattern to join the wires i used high amperage choc blocks due to the extreme heat and insulated them with good quality tape i even considered using small household electrical junction boxes as they are made of hard bakelite plastic its an easy repair a couple of hours if that and no more than a tenner Last edited by birdwood; Mar 20th, 2009 at 21:45. Reason: adding price

Mar 20th, 2009, 22:15	#4
scottishvolvo Premier Member Last Online: Nov 17th, 2023 00:15 Join Date: Dec 2004 Location: Glasgow	Drivers side one on mine is the same with normal bulbs. I have the connector but haven't got round to fitting it yet. __________________ Chris '98 S40 2.0T..Gone. 2000 S40 2.0 SE Auto and loving it. 2014 V40 Cross Country Please consider registering with the Anthony Nolan Trust, you could save a life.

Mar 20th, 2009, 21:52	#3
myatt1972 Senior Member Last Online: Dec 28th, 2023 01:04 Join Date: Nov 2008 Location: stafford	Have you got uprated bulbs fitted? If you have they will draw more current which could contribute to the melting. Keith...

Mar 20th, 2009, 22:17	#5
myatt1972 Senior Member Last Online: Dec 28th, 2023 01:04 Join Date: Nov 2008 Location: stafford	Im going to check mine tomorrow then, sounds like a common problem. Keith...

Mar 20th, 2009, 23:38	#6
stevo48 Premier Member Last Online: Jul 9th, 2020 20:08 Join Date: Dec 2007 Location: Halifax West yorkshire	Go to any good auto shop and ask for a pair of H4 connectors they come complete with brass spade connectors as opposed to mild steel connectors so you get better conductivity as the mild steel connectors tend to corrode causing high resistance.

Mar 23rd, 2009, 11:20	#7
ChrisRidett New Member Last Online: Aug 28th, 2020 15:12 Join Date: Feb 2009 Location: Maidstone View Photos By: ChrisRidett	Same here, Drivers side connector bust and cables cooked. Once replacements arrive from ebay will look at crimping them on. I'm also missing the circlular cover plate from the back - I wonder if that led to the corrosion/ melting.

Mar 23rd, 2009, 15:41	#8
motty New Member Last Online: Apr 2nd, 2009 08:53 Join Date: Feb 2007 Location: pirbright	Thanks for the replies chaps. Purchased some H4 connectors off of ebay and some 15amp connection blocks from Halfords. Hopefully this will do the job. Alan.

Mar 24th, 2009, 16:06	#9
motty New Member Last Online: Apr 2nd, 2009 08:53 Join Date: Feb 2007 Location: pirbright	Just had a quick look at what I need to do. I have to say there isn't much existing wire to work with (or room). Hoping I can strip back shielding on exisiting wire Ok and connect a connector block to it. Alan.

Mar 25th, 2009, 02:07	#10
adamsky01 back for now Last Online: Aug 17th, 2016 21:48 Join Date: Aug 2006 Location: gone	there is a service kit for this speack to rufe it aint dear i think thats the part no 30652035 but not sure ask rufe and tell him ur reg

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