Thanks for follow up.

Stepping in for my father here on the thread...

I have only lost the ONE driver side (left) low beam.

We ultimately ended up replacing the headlamp plug, again. I say again because the original factory plug had similar heat damage/degradation, and so we replaced it about 2-3 months ago with an aftermarket ceramic wiring harness/plug (this product: http://www.amazon.com/Hipro-Power-Ceramic-Headlight-Harness/dp/B005J6YUY2). We cut off old/original plug, spliced and soldered this one in.

Much to our surprise - the aftermarket plug got cooked. Melted the plastic shell covering the ceramic plug. The wires feeding in to the plug melted off part of their sheath. Pretty aggressive levels of heat & damage for the headlight!

So, in reverting to my father's original post - we checked the shunts, fuses, did a visual (cursory) inspection of the wiring under the hood, CEM looked fine, etc. - everything looked good.

Alas, as I noted above we gave up and just spliced in another ceramic aftermarket plug. I'm monitoring it now for similar failure - so far it's holding up, but seems substantially hotter than the other headlight.

And that is key here: the other headlight (passenger/right) side is just fine. Original factory plug, no problems.

We wished to fix the cause of the problem, but we just replaced the plug again - anticipating a repeat of before.

So if it's just the one headlight, does it make sense to check the alternator?

Is it possible that the headlight relay (is there more than one?) is bad and is affecting just ONE headlight?

Any and all ideas appreciated!

Thanks,

Greg Bales