Blew a bulb a day or so ago and went to change the bulb and found the loom connector had melted one of the two terminals. Its a short section of loom with a snap to connector that looks to be deliberately replaceable.

Is this a know issue and any ideas what caused it? The bulb filament is intact, but it's burned off one of the two electrical connections on the bulb socket.

http://www.freel2.com/gallery/albums/userp...ection.jpg

http://www.freel2.com/gallery/albums/userp...ection.jpg
http://www.freel2.com/gallery/albums/userp...ection.jpg

Note .... it is easier to view the photos by pressing 'gallery' button under your message, much clearer.

Can't help with the connector, although this is a classic example of a poor 'mechanical' joint as opposed to a electrical 'solder' joint. I do understand why there is a plug/socket there though.

Here is a thread which may help you .....
https://www.freel2.com/forum/topic30484.html
found it by 'Search' button on top blue bar.

Cermaic HB3 bulb holder.

https://www.ebay.co.uk/itm/9005-HB3-CERAMI...SwY45UQ-C2

Yoi will need to solder the leads onto the short loom and heat shrink sleeve them.
Good Luck
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Thanks.

Just spoke to LR dealer parts depot and the small lead isn't listed as available separately. Whole headlamp unit required! That ebay lead looks worth a go.

Cheers

One side of mine went like that and I replaced with similar ebay plug. The cable on them is unnecessarily thick but otherwise work fine.

I would advise crimping it in with butt crimps rather than soldering as the heat of the lamp conducts down the cable which gets quite hot. Probably wouldn't get hot enough to melt the solder but still.

Anyone disturbed that that type of heat on that connection just seems simply wrong?

"I would advise crimping it in with butt crimps rather than soldering as the heat of the lamp conducts down the cable which gets quite hot. Probably wouldn't get hot enough to melt the solder but still."


I have to disagree with you on BOTH counts. I have never heard so much nonsense, solder melting ?

I have spent my life's work in electronics and can support my above posts with actual knowledge.
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Well, I only say that from personal experience I have had a joint to a lampholder come unsoldered before because of heat down the wire from the lamp. It was a bigger lamp than an HB3. When you buy the replacement HB3 lampholder you will see it is moulded in ceramic and the wiring is silicone insulated due to expected heat.

@AndyPP

Are you sure the bulb specs are right, and is it from a reputable source? The remaining bulb side pin looks far too small, which would cause a localised hot spot. I mention it as I bought some cheap un-branded, non E marked bulbs from Amazon (not realising they where so dodgy) and they caused me the same damage.

I replaced mine with genuine Delphi connectors, but I really like the idea of these ceramic connectors that have been linked to.


On the subject of melting solder in a car, I had a car come in with an issue where the cabin blower no longer worked, and after much head scratching pulled the lid off the supply relay to find the solder in the internal contacts had melted and caused the issue. So it does happen.

It's not un-usual for me to make cable joints for 70amp+ supplies on 12v systems and so long as they are correctly jointed (twisted correctly, offset joints, sealed joints, mechanically isolated etc) I've never had a problem with solder. I guess if you get to the lower melting point of solder, you're having a thermal event anyway

It was a bulb replaced at the last mot by my garage, I had the ring 120%+ bulbs in before. It looked like a decent ish quality bulb the garage fitted but can't be sure. The metal pin on the bulb connection was totally burnt away!

The insulation on the wires inside the headlight was an absolute that to get off, its like the wires were hot dipped in the insulation and would not strip off. I had to melt the insulation off the wire!

It seems to be working OK. Put some osram 120% bulbs in and its not caught fire yet!

Just checked photos and it was a lucas 9005 12v 60w bulb the garage put in