Author Topic: headlamp light dim, lights up normally if I wiggly the harness around.  (Read 3690 times)

Offline Macaroni_Sackaroni

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Not sure what the issue is, I noticed one of my headlamps was dimming, thought I needed to buy a new one, but realized I just have to give the wire plug in thing a wiggle and then it looks normal.  :o ....

im guessing its the connector.. so im wondering if i can put some dielectric grease inside it to help things??? not sure if this is okay though..
« Last Edit: November 18, 2016, 07:20:54 pm by Macaroni_Sackaroni »

Online bd

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Re: headlamp light dim, lights up normally if I wiggly the harness around.
« Reply #1 on: November 18, 2016, 07:46:14 pm »
If you mean the plastic electrical connector that plugs onto the back of the headlamp, liberally rinse the connector terminals and lamp contacts with WD-40, then plug and unplug the connector several times to burnish the connections.  As long as the terminals aren't disintegrating from metal fatigue, cleaning the connections should take care of it.  Once you're done servicing the connections, you can pack the connector with an anti-corrosion compound.
Rich
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Offline Captain Swampy

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Re: headlamp light dim, lights up normally if I wiggly the harness around.
« Reply #2 on: November 18, 2016, 10:31:32 pm »
Steal, I mean borrow a nail file from your wife. Trim it to fit, and then clean up the connector. You can buy new connectors. Use heat shrink butt connectors to attach them.
1987  350TBI 700R4  4X4  4.56 gears  33" BFG All Terrain


http://forum.73-87chevytrucks.com/smforum/index.php?topic=32209.0

Offline hatzie

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Re: headlamp light dim, lights up normally if I wiggly the harness around.
« Reply #3 on: November 19, 2016, 12:16:51 am »
Clean the terminals up with WD-40 and elbow grease the way Rich suggested first.  The Packard 59 terminals in the H4 headlamp plugs are very heavy duty.  As long as they have not been badly overheated to the point that the plug is melted or turned into a green lump of corrosion by road salt, so you can't recognize them as terminals, they can be salvaged.

If you need to replace the terminals...  Don't use Butt connectors.  They're not a reliable long term repair.

If the terminals are shot you can buy replacements for $0.25 each or less.  They are Delphi Packard 59 series Female lock tab terminals. 
Extract the failed terminal from the headlight socket just as you would a Packard 56 terminal. Crimp the replacement directly onto the wires after clipping off the failed terminal and stripping off the right amount of insulation.  Once they are properly crimped on slip them back into the connector shell.
This is the Packard 56.  The 59 terminals are just a little bigger. 

Use five cavity or two cavity "double wire" two operation crimp tools.  Crimp the conductor(s) and then crimp the insulation retainer wings in different slots.  Much more versatile than the single operation tool that crimps both at the same time since you can use them across multiple connector families.
The professional grade tools last longer and tend to hold thier value at around 75% of new if you take care of em.
@ $100 Ratcheting Delphi Five Cavity "W" Crimp tool 12085271
@ $100 Double wire Packard 59 two cavity "W" crimp tool 12040070
How to crimp connectors.
« Last Edit: November 19, 2016, 12:20:10 am by hatzie »
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Offline Macaroni_Sackaroni

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Re: headlamp light dim, lights up normally if I wiggly the harness around.
« Reply #4 on: November 19, 2016, 04:01:21 pm »
Clean the terminals up with WD-40 and elbow grease the way Rich suggested first.  The Packard 59 terminals in the H4 headlamp plugs are very heavy duty.  As long as they have not been badly overheated to the point that the plug is melted or turned into a green lump of corrosion by road salt, so you can't recognize them as terminals, they can be salvaged.

If you need to replace the terminals...  Don't use Butt connectors.  They're not a reliable long term repair.

If the terminals are shot you can buy replacements for $0.25 each or less.  They are Delphi Packard 59 series Female lock tab terminals. 
Extract the failed terminal from the headlight socket just as you would a Packard 56 terminal. Crimp the replacement directly onto the wires after clipping off the failed terminal and stripping off the right amount of insulation.  Once they are properly crimped on slip them back into the connector shell.
This is the Packard 56.  The 59 terminals are just a little bigger. 

Use five cavity or two cavity "double wire" two operation crimp tools.  Crimp the conductor(s) and then crimp the insulation retainer wings in different slots.  Much more versatile than the single operation tool that crimps both at the same time since you can use them across multiple connector families.
The professional grade tools last longer and tend to hold thier value at around 75% of new if you take care of em.
@ $100 Ratcheting Delphi Five Cavity "W" Crimp tool 12085271
@ $100 Double wire Packard 59 two cavity "W" crimp tool 12040070
How to crimp connectors.


new connector should be good i noticed that most of the aftermarket headlamps have shorter metal prongs than the old style factory, makes it hard for the wire to stay plugged into the headlamp...

ill give a clean with some wd40 since i dont need to drive my truck its just a project.
but its really that bad ill buy a new connector.