Headlight connector melted

[MikeC5]

I have a 95 Legacy wagon which has halogen-style headlights (small bulb, not like sealed beam headlights). I noticed the driver's side light was out tonight, looked in there and found the plastic connector partially melted and the top spade terminal quite burnt looking. Also noticed the bulb was loose because the spring wire catch on the plastic headlight body had broken off. I determined that this spring must make good contact with the bulb flange for grounding. So apparently things were heating up due to a poor ground connection - Is this a common problem?

[Legacy777]

The bulb doesn't ground through the spring.

It is common for the connectors to melt on the 2nd gen legacies. I helped a friend with her 96 legacy. It had the same issue. We got a set of connectors off the web.

This is what we got
http://www.comagination.com/parts.htm
H4 / 9003 Female plug connector pigtail

[MikeC5]

Thanks 777. That's the ticket.

[lunes]

few months late on this, but I had a light plug melt on my 90 legacy, and a friend found me one of these connectors with about 4 inches of wire on it at Wal-mart for less than 10 bucks...