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Old 05-21-2006, 10:41 PM   #1
jpapanas
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Member#: 65110
Join Date: Jun 2004
Chapter/Region: TXIC
Location: Houston, TX
Vehicle:
2003 LSE Wagon
Silver

Default Low-beam headlight connector melted

I have a 2003 Legacy SE Wagon. The passenger side low beam doesn't work anymore. The high beam is fine. When I checked the headlight connector, I noticed that one terminal is burnt and melted. Why is this happening?

The bulb that is in there now is an H 9007 12V 65/55W, but the owners manual calls for a 9007(HB5) 12V 60/55W. Are these bulbs compatible? The low beam wattage is the same.

How do I fix the connector?

Passenger side headlight connector:

Bulb: H 9007 12V 65/55W


Regards,
Jim
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Old 05-21-2006, 10:46 PM   #2
Wiscon_Mark
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Join Date: Aug 2005
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Location: Stevens Point, WI
Vehicle:
1995 Legacy OB 5MT
2003 Forester X 5MT

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It's either a defective harness, or the bulb is drawing to much power from the car.

From what you told me, the bulb probably isn't the problem. To fix it, you need to get a new harness.
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Old 05-21-2006, 10:51 PM   #3
Patrick Olsen
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1997 Legacy 2.5GT
QuickSilver Metallic

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Sounds like a warranty fix to me. Are you still covered?

I agree that it sounds like a wiring harness issue. If you're no longer under the bumper-to-bumper warranty and need to fix this yourself, I recommend taking the grounds from both headlights and running them directly to the ground lug on the battery. I've seen issues before with headlight harnesses overheating, and a better ground seemed to fix the problem.

Pat
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Old 05-21-2006, 11:11 PM   #4
jpapanas
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2003 LSE Wagon
Silver

Default

Quote:
Originally Posted by Wiscon_Mark
From what you told me, the bulb probably isn't the problem. To fix it, you need to get a new harness.
Can you get just the headlight harness? What is the part number?

Quote:
Originally Posted by Patrick Olsen
Sounds like a warranty fix to me. Are you still covered?

I agree that it sounds like a wiring harness issue. If you're no longer under the bumper-to-bumper warranty and need to fix this yourself, I recommend taking the grounds from both headlights and running them directly to the ground lug on the battery. I've seen issues before with headlight harnesses overheating, and a better ground seemed to fix the problem.
I'm no longer under the bumper-to-bumper warranty.

Which of the three wires on the connector is ground? Can you describe exactly how I would modify the harnesses to connect the grounds to the ground lug on the battery?

Regards,
Jim
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Old 05-21-2006, 11:28 PM   #5
Wiscon_Mark
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2003 Forester X 5MT

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easy enough to better ground it. Just take the ground wire on the harness (not sure which one, but someone else could chime in with the info) and splice it to a nice thick wire that taps right into the negative battery cable. Or you can ground it to the body, which has ground wires all over it.

As for the part # for the harness, I have no idea. The dealership fixed several harnesses for us because they were acting up, both under warranty and not under warranty for free. But our dealership kicks major ass, so I doubt you'd get that kinda deal. You can always get the part # from them though.
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Old 05-22-2006, 05:52 AM   #6
NiTRoN
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over 250,000 Miles

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I've uploaded diagram for

03 Legacy Headlight Wiring

CLICK HERE FOR PDF


-enjoy..
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Old 05-22-2006, 11:48 PM   #7
Patrick Olsen
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Location: Where the Navy sends me...
Vehicle:
1997 Legacy 2.5GT
QuickSilver Metallic

Default

Quote:
Originally Posted by jpapanas
Which of the three wires on the connector is ground? Can you describe exactly how I would modify the harnesses to connect the grounds to the ground lug on the battery?

Regards,
Jim
Off the top of my head I don't know which is which, but it should be pretty easy to figure out with a multimeter. Either that or google for "9007 headlight ground" or something like that, I'll bet someone's got the info on their website.

As for modifying the harness, you just need to splice into the ground wire and run a wire (16ga is probably good, maybe 14ga) over to the battery. Put a ring terminal on the end of it and bolt it right to the negative battery cable lug. The harness should already be grounded to the body, so I wouldn't bother adding another ground to the body. The point is to go straight to the battery for the best ground possible.

Pat
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