D1 Headlamp Connector

[d1owner]

My headlamp connectors (both) seemed to be corroded and melting. Does anyone know where I can get thes connectors as a replacement. I spoke to the dealer. LR does not carry this part. They want you to change out the entire wiring harness for what should be a 20-30 min job.

Any advice also appreciated.

 

[monkeyboy]

I had a failing low beam d/s connector. Stopped at the local O'reillys (sp) and bought a normal replacement. Soldered and shrink tubed it - should be good for a while

Some replacement connectors you find will have teeny wires. Look for larger wires, keep 'em short, solder, dont crimp.

KAA

 

[d1owner]

Keith,

Thanks for the info. Unfortunately, Idon't have an O'Reilly's where I live. I saw a similar part at a Pep Boys, but it had very small wires as you mentioned.

BTW, what is shrink-tubing?

 

[justinhaaga]

My passanger rear rotted, I took it out and got some needle nose and tighten down the metal connecter, even though the plastic is shot to hell this gives it a tight connection on the light, then with some black tape around it was good as new.

 

[monkeyboy]

Just keep the small wires short and keep an eye out for a better set of connectors. Got a truck stop near?

Shrink tube? Usu black plastic, somewhat shiny tubing. Slip it over the soldered joint - after it cools! - heat it with a hair dryer and it will shrink up and keep the joint insulated & dry - same effect as electrrical tape, just much neater.

 

[Rocky]

Headlight is common, should be possible to use a generic connector

 

[d1owner]

I did the short-term fix by cleaning the contacts, pinching the metal spades (contacts) closer, etc. The plastic on the black-wire lead (on both connectors) is melted and therefore does not provide adequate support for the spade. I have been unable to locate a new 9003 socket. A junk-yard near me apparently received a fresh 94 Discovery from an accident. I'll need to call to see if I can harvest this part if it is in any better condition than mine.

I seen on the net that a 9003 bulb is the same as an H4. Does anyone know if this is true. At an auto store today I picked up both bulbs and the connectors are configured the same. It looked like the H4's prongs were slightly larger than the 9003. But this could be because it came from a different manufacturer, etc.

My preference is actually to purchase a kit, with spades and the plastic connector. Then I can crimp and/or solder the wires and then insert into the connector.

 

[oberdahill]

There are upgrade/replacement connectors you can buy. I went to brighter lights on my Volvo and replaced the headlight sockets with heavier wire and (higher) heat resistant socket. I'll try and get the brand of socket when I get back to Germany. Try www.automotivelightingusa.com and look for the wiring harness. The local auto parts place should have the harness's too.