bluesuby Posted July 11, 2019 Posted July 11, 2019 2005 LGT Wagon. A few years ago I upgraded my stock H7 bulbs with 55 watt "off road" bulbs from Phillips. Unfortunately, one buib socket suffered a meltdown. The online vendor helped by recommending a replacement socket made to withstand high temperatures. The replacement required cutting the wires at the socket and attaching brass terminals (I included soldering the terminals in addition to the wrap-around tabs) which are concealed inside the replacement socket. Result is a push on-pull off socket which plugs onto the H7 terminals. Everything was fine until today when I thought my bulb had burned out. I found that the bulb is ok, and by arranging the wires by pulling them apart gently got the bulb to stay lit. I know this will not last and will fail some night not Winter when it's really cold outside. I found a replacement harness in Advance and Auto Zone. Both are rated for higher temperatures, but since they are not stocked in local stores I need help. Advance sells a "Techsmart harness" part # F90007" which is an 8" length with "female" fitting on one end (for the terminals on the H7 bulb) and a pair of "male" fittings on the other end which are for connecting to the main harness. They appear rather large and I cannot locate any connection which would accommodate them. Auto Zone sells a Dorman 645-994 which lacks a good description. It looks like a pair of female connections on one end of the wiring but the photo of the other end doesn't show much. Their online help with repairs is down now and doesn't seem promising. The Dorman is twice the price of the Techsmart (17.99 versus 8.99) but this could be a case of not getting the best part based on price. I need help. If anyone can walk me through the harness replacement, and if anyone has comments on either or both options I certainly appreciate any/all comments.
Max Capacity Posted July 11, 2019 Posted July 11, 2019 Search "covertrussian" threads. I think he has good info on headlight harnesses or fix's. Sorry, sounds like you worried about paying $17.99 for a part... that's nothing. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here
apexi Posted July 11, 2019 Posted July 11, 2019 Same thing happened to me with regular h7 bulbs. If the replacement bulbs are 55w like the stock bulbs are, I don't see how they're generating more heat? Anyway, I think the melting problem is caused by a poor/loose connection. I know the bulb was probably fully seated, but I mean it probably just didn't have a tight connection. I had issues with one of my headlights having a loose connection at the bulb which I fixed, especially in the winter when the bulb wouldn't work at all sometimes, but the other side that I didn't touch is the one that actually melted a little on me.
08SpecB_DE Posted July 11, 2019 Posted July 11, 2019 Is there a reason you want a piggyback style harness? A normal H7 harness is under $4 from Advance. If you know your splices are solid, check terminal tension. There should be some resistance in the female side.
bluesuby Posted July 12, 2019 Author Posted July 12, 2019 Thank you all. The "Techsmart" harness I also found (later) on Rock Auto. It's a product of Standard who has been making quality ignition/electrical parts for years. I'm looking for something I can trust. Cost is not a factor. I think Dorman has a lot of parts but they are just repackaging parts from other manufacturers. The terminal tension feels ok, but what is upsetting is how the bulb lights up by manipulating the harness. I'm thinking a broken or faulty wire concealed by insulation.
Max Capacity Posted July 12, 2019 Posted July 12, 2019 I agree, Standard is a good choice. I remember buying there stuff back in the early 1970's, for my 1961 Chevy Impala 235 straight 6 with a powerglide. I was 16y/o then. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here
bluesuby Posted August 15, 2019 Author Posted August 15, 2019 Due to very hot weather, I had not tried to replace the wiring harness until today. I traced the "plug-in" end and the wiring disappears through a very small hole in the headlight assembly. Worse yet, even if I pull the housing apart, there are connectors on both ends of the harness, so how do you route the wiring through this small hole without cutting it and splicing it once the wire passes through. This can't be right....anyone have an explanation?
08SpecB_DE Posted August 20, 2019 Posted August 20, 2019 One end plugs into the factory connector and the other end plugs into the bulb. The part you have is not meant to replace the factory wiring.
bluesuby Posted August 25, 2019 Author Posted August 25, 2019 One end plugs into the factory connector and the other end plugs into the bulb. The part you have is not meant to replace the factory wiring. So where is the factory connector?
08SpecB_DE Posted August 27, 2019 Posted August 27, 2019 The connector that is attached to the back of the bulb. Unless you want to extend the connector that plugs into the bulb 8" longer, throw it away. What you bought is worthless, I dont know how else to word it. You're not looking to replace the wiring within the headlamp, all you need to do is cut the burnt, old connector off, splice in the new connector and call it a day. I'm not a salesman so I'm not going to make you feel warm and fuzzy inside while reaching into your wallet. $5 and 15 minutes of your time is all you need.
apexi Posted August 27, 2019 Posted August 27, 2019 I don't completely follow what's going on, but as I mentioned earlier one of my connectors melted and got messed up with standard 55w h7 bulbs. Cut the old connector off, soldered the connector below to the existing wiring, and everything is fine. Wire gauge on the pigtail was thicker than the oem wiring, so I'm not worried about it at all. https://www.amazon.com/Putco-230007HD-Automotive-Lighting-Standard/dp/B001M9YJB4
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