6-Pin Headlight/Tail Connector — Heat & Melting Issues (2302238-1 / 8992188-01)

Localised melting at lamp connectors is nearly always contact-resistance from weak terminal tension, not a fuse/bulb problem. Replace the connector and terminals to restore a cool, low-resistance joint.

What To Look For

• Browned or charred plastic near a single pin
• Flicker, dimming or intermittent lamp operation
• Loose terminal that won’t “snap” in the cavity

Repair Steps

1. Replace the connector housing and the affected terminals.
2. Check crimp height and terminal seating; do not upsize fuses.
3. Verify full latch and perform a load test.

Recommended parts: 6-Pin Headlight/Tail Connector Kit (2302238-1/8992188-01) 

Installer Note

Any sign of discolouration on adjacent pins warrants replacing those terminals too.