Fox Body Headlight Connectors
 

Hey Guys,

I recently started having problems with my headlights. It looks like they are getting hot and melting the female connectors. Are there any replacement parts out there and where can I get them? They went out on me last night at about 9PM. Bad time to be driving with no headlights.

year 1

If they're getting hot you should maybe check the amperage going to them.....There should be no reason for them to get hot enough to melt the connectors

If the wires are getting hot, check your ground leads for the headlights. They are located on either side of the front apron.
This should help:
Attachment 154227

My headlights are completely gone now. What can I do and where can I get them fixed? NIck's has closed so there is no chance of going there. I was told that it may also be electrical. Can I replace the electrical system for my lights?

Do your high beams work or not? It's not hard to wire in a separate relay controlled headlight system. I suggest two high amp BOSCH relays, you can use the factory headlight switch to turn them on and the same goes for the high beams. If they're not working you'll need a total of 4 relays.
Just take the car to a trusted independent shop, I'm sure someone you know has an old European mechanic they trust. Old school European dudes are usually the better mechanics, they are also usually very good with wiring and can trace your problems. Keep us posted on what happens.
SS

My High beams were working then they stopped. I've had to drive at night twice without them. I work for the Budd's in Oakville. I'm sure one of the dealerships should be able to fix my problem. I'll get back to you tomorrow on what happens. Thanks for the help.

Have you tried replacing the multi-switch? The stalk that controls your high beams, turn signals and wipers....... It's real easy to replace, but make sure you get one from a non-airbag car. I think that may be your problem.
SS

Whatever the problem is it melted my connectors.

Sounds like a bad ground. Have you even checked the grounds or done any sort of work/testing on the system?
SS

No I have not. I had the connectors replaced and they all work again.

Here is what it's down to. I had my female headlight connectors replaced. My grounds are connected. They worked for a bit then they stopped. My highbeams are working my parking lights work. The only thing that doesn't work are my headlights. I'm currently looking at getting a new headlight switch to see if that is the problem. Is there any way I can test the old one before I buy a new one? I don't want to buy it if I don't need it. Also where can I get these relays from and where do they connect? Are they like the headlight switch?

Thanks for the help SS, Jonathan.

I was afraid this would happen, though I thought the new plugs would melt as well. You will either have to diagnose the whole headlight wiring system or build a new one. If you cannot figure out where to buy relays, then wiring might not be for you.
Relays are switches. Power (+) in, power (+) out, ground (-), and a switchable power on (+). Power in comes from the battery, power out goes to your headlight (low beam or high beam requires separate relays and power), ground goes to ground, and switchable power goes to your headlight switch. For high beams, I dont remember if there is a connection at the headlight switch but you would most likely run that to the multi switch on the steering column. You will require three relays, headligh low beam, headlight high beam, and parking light. You could redo the whole lighting system, including the tailights if you wanted to. It just comes down to how capable you are with wiring and if you have the diagnostic ability and creativity to find and create circuits.
You would get relays from an electronics parts store/supplier, and you dont run the crap they sell at Canadian Tire. You would need high quality Bosch 40-50 amp relays to hold up to the current draw from the lights. Honestly, if I were still in Toronto I'd offer to help but since I'm not I can recommend you to a great shop where I used to do all my work. A friend of mine still works there, and he's just as much of a Mustang junkie as I am. The owner of the shop is also a champ at fixing wiring and diagnosing issues, so it's a very well rounded team especially when it comes to Mustangs! Let me know if you want to have someone take care of this headache for you and I'll pm you the info.
SS

I'm going to try replacing the switch to see if thats the problem. If it isn't then I'll get back to you tonight and you can send me the info for the shop. I'm actually in Oakville, but I travel to Toronto almost every weekend.

Jonathan.

Is it popping the fuse or anything when you turn the lights on. Also pull the light switch out of the dash and see if there is any corrosion or burn marks
Other place to look is behind the rad support for a short in the wire