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240 headlight relay connector melted 200

posted by  Garyh on  Sat Dec 13 10:29 CST 2003
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last visit: Sun Apr 15 11:44 CST 2012
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I worked on my son's 1989 240 a couple of weeks ago finding brake light problem due to bulb failure relay (re-soldered and worked). Last night headlights went out and found melted headlight relay connected melted at the + main supply. Thinking this is what caused the bulb failure relay to fail, since before that he smelled burning.

First, thanks to brickboard FAQ; diagnosed bulb failure relay first time and going for the headlight relay this time.

Two questions

Connector obviously heat from short or bad connection. Any ideas where to check for root cause?

What is best fix without removing entire harness (I know that is the best way)? Is splicing a new connect a good idea?

Thanks

Gary






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