A word of warning with our headlights

satrnbmb · Post by **satrnbmb** » Sat May 20, 2006 1:46 am

OK everyone, I've had 2 instances where my low beams refused to function for about 20-30 minutes. There was no apparent rhyme or reason for it. High beams would work, but low beams (and fogs) just refused to turn on. The last time this happened, there was a definate odor coming from my dashboard that started when my lows came back afterwards for no reason. It smelled like melting plastic. I thought it was the short ending during that time. I never smelled it again. During the heavy rains we had last weekend, I smelled it again while I was driving with my headlights on. This time, my high beams were on at the same time as my low beams and fogs. It was as though. I was holding the lever back torwards me, even though I wasn't touching it. Nothing I did would release my high beams. Even after the rain ended nothing would release them. I got myself a new part and as I was installing it, I found something very interesting. I took these with my camera phone which I have to admit I'm not fantastic with...
These two are of the back of my switch assembly. The plastic has melted down and one of the connectors is burned.

These are of the harness itself. It's been melted severely enough to contribute to the short problem I think.

I'll try to take better pictures once I get some time here. If you guys smell any melting plastic while your lights are set to on, you really need to have this checked out.

Ifixyawata · Post by **Ifixyawata** » Sat May 20, 2006 1:53 am

You're running stock wattage headlights and everything?

03sxt · Post by **03sxt** » Sat May 20, 2006 6:28 am

I've read this somewhere else, too. Others have had problems with this.

satrnbmb · Post by **satrnbmb** » Sat May 20, 2006 10:16 am

Ifixyawata wrote:You're running stock wattage headlights and everything?

Bone Stock headlights that were on the car when I bought it. The foglight bulbs have been replaced, but they're regular bulbs not silverstars or hyper whites or anything.

The ONLY thing that could have any effect on my electrical system I can think of is my UDP and alternator ODP. I even have a stock stereo system.

kirktalife · Post by **kirktalife** » Sat May 20, 2006 10:29 am

see the problem is that your runnin stock headlights

Panhead · Post by **Panhead** » Sat May 20, 2006 4:33 pm

maybe too much power, heated the plastic and then there your short. that what im guessing, im not a expert on this.

scneonchic · Post by **scneonchic** » Sat May 20, 2006 6:52 pm

I had my acutal headlight bulb sockets melt on me about 3 months ago. But It was because of the higher wattage street glow bulbs I have. I went to advance auto and bought some higher wattage heavy duty headlight sockets and wired them in.

Before I figured out what it was, I would smell something burning when I drove the car w/ the lights on (at night) but I couldnt figurue out what it was. I didnt see smoke or anything. Finally one night, I went to drive it and my headlight was glowing orange and I thought it was just a wierd defective bulb, but when i took it all apart I discovered the burnt sockets.

Knoxville_R/T · Post by **Knoxville_R/T** » Wed May 24, 2006 12:30 pm

This is a problem wit almost all the neons. I believe the 01's have the most problems. I had the problem on my old 01' and my buddy at work just had that happen to him too(01' also).

There is a post somewhere with tthe part numbers for the items that need to be replaced. I think it is around $100.

Post by **jonnymopar** » Wed May 24, 2006 2:21 pm

I had my 03 apart to do the PT Cruiser switch conversion and man are these things flimsy! Mine wasn't melted, but they are damn fragile.

marakka · Post by **marakka** » Wed May 24, 2006 4:23 pm

The PT cruise switch conversion? WTF is that?

grambo · Post by **grambo** » Wed May 24, 2006 5:28 pm

^X2??

caustic neon · Post by **caustic neon** » Wed May 24, 2006 6:01 pm

^x3???

Post by **jonnymopar** » Wed May 24, 2006 6:27 pm

marakka wrote:The PT cruise switch conversion? WTF is that?

http://forum.2gn.org/viewtopic.php?t=3104

gofastrt · Post by **gofastrt** » Mon May 29, 2006 10:13 pm

i had this same exact problem took the words right out of my mouth i put NOKYA headlights in mine and sometime after that my low beams only worked when they wanted to so i want to a junk yard and got a new swtich and everything like he did and everything worked fine for awhile and then my fog lights dont turn on now,...o well atleast i got headlights and i took the NOKYAS out to just incase

Beboneon · Post by **Beboneon** » Mon May 29, 2006 10:51 pm

This is somewhat a problem with Chrysler connectors. It is most common on headlight bulb sockets. It is caused by an incomplete connection within the connector itself. These problems are hard to find & have been known to cause fires.

lilolneon · Post by **lilolneon** » Mon May 29, 2006 11:11 pm

mine is very minorly, and slightly singed