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Trying to find wiring harness for the headlights. They melted.

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Try the dealer they should have just the plugs with wires and you will have to connect them to the original wires or you can look on web at parts stores see if they have them you can get the factory harness but would have to replace the entire underhood harness for the headlites and will melt again

Posted on Jul 16, 2010


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The headlights fuse on my montero 95 keeps shorting out, a thin wire at the headlight switch plug was in fact melted against the metal housing at the back of the steering wheel, i bridged that wire all the...

Observe the way the fuse burns out.
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Melted wires indicate a heavy load or a short circuit.
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I have no low-beams. I replaced headlight switch,fuse and both bulbs. Still nothin. The wiring harness seems a bit burnt...could this be an issue?

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1995 chevy suburban headlights won't come on but running lights work (headlights previously worked). No high or low beams, no high beam indicator light. Bulbs seemed to be ok, fuses seem to be ok....

Common for the wire harness on the switch to go bad. Inspect the wire harness where it clips on to the switch and look for any signs of damage.

The plastic heats up from the current running through the switch and causes it to melt and then you loose connection caused from melted plastic between the contacts from the harness to the switch.

There is a upgrade to the headlight harness which is larger then the ones that came with the Suburban to address this issues. You can get them at the dealer or NAPA i believe.

Good luck and keep us posted. Thank you for using fixya and stay safe.


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If the car was purchased new and the bulbs are the original bulbs, then I don't believe they would. In that case, I would be lead to believe it is an issue with the harness, which could cost upwards of $100. You could splice in a new wire (14GA and better recommended). I don't think headlights are covered under warranty, but you could give it a shot and see what they say.

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Headlights does not work on high or low

For has had a problem with their headlight switches melting for quite a few years.
If you take the headlight switch out you will likely see that the plug is melted and the power wire is not making contact any more. Go to Ford and get the new upgraded headlight switch and wiring harness wire it in and it will be good.
Contact me if you have more questions
also visit go to the FAQ and BLOG look under ford or lights and you will see and entry to this effect.

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