shellback91 1,300 Posted October 23, 2021 Howdy Gang! Today I noticed my drivers side headlight was out so I set about repairing it. I have the KC HiLITESH4 headlights. After removing the headlight assembly I went to unplug the connector and found out it wanted a fight. I could not unplug the connector to the bulb. After a little closer inspection I notice the darn thing was melted to the prongs. This is probably why it stopped working. A few minutes later, after busting the bulb all to pieces in the lamp assembly trying to get it loose, I decided to cut the wires. Last year I had these H13 to H4 Wiring adapters replaced after the passenger side adapter was giving me fits. I kept the old ones because I'm a hoarder of sorts. I used one of the old ones and a new bulb to get it working again. Onto the point of this , my question is has anyone dealt with this type of thing? Any recommendations on brands to use that won't melt? I did read this is common with some H4 bulbs so I may be SOL. LED's are out of my price range so I am not inclined to go that route. Stock Lamps suck but I could go back if this happens again. After cutting the wires and prying the outta the parts involved this is what it looked like. 1 Share this post Link to post Share on other sites
Stacey and Scott 946 Posted October 23, 2021 This is common when dealing with hi temp lighting, stock connections are spec'd to a minimum tolerance as far as temp ratings. Easiest solution is to replace the plug with a industrial grade or, remote the plug itself 2 or 3 inches away from the light using a thermal (high temp) wire and use a high quality blade terminal (again hi temp) to land the wires at the light. The upside is the remote plug makes it a lot simpler the dis/connect the lights in the future and no more melting possibly shorting out of your lights when you're tearing down a dark road. 4 Share this post Link to post Share on other sites
theksmith 3,069 Posted October 23, 2021 you want one with a ceramic high-temp connector at the bulb, along the lines of these... - i don't know a specific brand, but that's the sort of thing you're looking for. 1 2 Share this post Link to post Share on other sites
shellback91 1,300 Posted October 23, 2021 Thanks gents. I was told by the shop that sold me the replacements that the KC HiLITES adapters were crap. Passenger side would not completely seat so we replaced both. I will be purchasing me some ceramic based ones. I am looking into the KC adapters to see if they are ceramic based too. They are proud of their adapters so they are a little more expensive than most. 2 Share this post Link to post Share on other sites