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DETAILED instructions on how to replace burnt headlight bulb connectors.

22743 Views 9 Replies 5 Participants Last post by  SouthernFront26
I have found a lot of helpful information on this site, so I decided to add some of my own. This is for those of that ran high watt bulbs and melted your stock connectors, or if you plan ahead and are going to run high watt bulbs. If one of headlights is dim, then you have started to melt the connections, replace them now so they both don't go out on you in the dark like mine did. The replacement connectors can be found at Autozone or your local parts store for about $12.
1st , disconnect the positive side of your battery, and reach down and turn the large white ring a 1/4 turn, and pull out the bulb and stock connector.

2nd disconnect the bulb from the stock connector, you might have to use a screw driver as the lever does not always release, you can see the damage from the high watt bulbs.

3rd, grab your new connector, and strip the ends. You can shorten them, but I kept the long to make removing the headlight bulbs easier.

4th, crimp your butt connectors on, and and slide some heat shrink over them, you can solder the wires if you prefer.

5th, Slice the tape on the stock wires, and cut your 1st wire, close to the connector b/c the wires are not that long on the battery side. Cutting and connecting one at a time will insure you line them up right, it is D shaped so just follow the order left to right.
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I used these on my high wattage bulbs. I installed them right before upgrading my bulbs. No problems in over 3 years.

9004 / 9007 Factory replacement bulb socket upgrade kit
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