Low Beam Headlight socket keeps getting burnt and melted

try superbrightleds.com . . . .

 

I'd be checking the ground for that light.

 

Yeah, that's what I was thinking. Headlights get hot, but they SHOULDN'T get hot enough melt the connection. You have a wiring issue, not a connector issue.

 

Good day i have the same trouble with my 2008 i was wondering if u found out what the problem was .any help would be awome

 

Many head light connectors you buy are only 14 or smaller gauge wire. You need a good quality 10 or 12 gauge wire and proper size spade terminal connected to it. Melting is from heat, heat is from high resistance. High resistance is from too small wire gauge, or poor quality terminals, or loose or poor fitting terminals.

 

The ground in the harness couldn't cause heating in the connector. It's the lousy connectors internal contact wipes, they're too thin and made of the wrong alloy. Look for a ceramic American-made connector. Solder the wires of the connector to your harness and use a couple of layers of heatshrink to insulate the connection. Apply a little anti-oxidation paste such as NyLox to the bulb contacts (used to protect copper-aluminum bonds.) That will be a life-time repair.
You should also replace the bulbs because the contacts have been damaged due to heat & corrosion.

 

Yes, you need a Motorcraft pigtail kit, HU2Z-14S411-KA (WPT 1497) which has silver plated terminals and 14 gauge wire, 10 inches long to acgt as a heat sink to keep the terminal cooler. The problem with this H11 bulb is it gets way too hot at the 2 terminals and they overheat and begin to get loose. This creates even more heat until the connector melts. The production terminals are usually tin plated and the wire gauge is usually 18 gauge which is too small and won't wick away any heat. So, install the pigtail kits and don't shorten the wires because you want as much heat sink as you can get.

 

The melting is caused by high current draw in the low beam circuit, not the hot bulb. Look for a connector with corroded terminal, when cleaned and securely reconnected the problem will go away. Look at the large connector that connects the wire harness from the light to the chassis wire harness.