Broken headlight connector clip

[Hutch7344]

So my coworker backed into me and broke my headlight a few days ago. I bought a replacement headlight (Used) but when taking out the old one I noticed the clip that holds the connector into the headlight assembly is broken. Obviously this was broken before he hit me so I figured it wouldn’t be a problem, but the new headlight keeps turning on and off while driving. The connector isn’t sliding out but it’s almost like it needs the pressure from the clip to work. If I’m standing there with the headlights on I can’t plug it in any further, but when I apply decent force and hold it pushed in then the headlight turns on. So obviously the clip applies some kind of spring action that doesn’t work just being plugged in. Any idea on how to rig it up to work without soldering in a new connector? I thought about glue or epoxy or something but I honestly don’t think it would apply enough pressure. Thanks in advance

[fR3ZNO]

IMHO, your best bet would be to buy a new connector housing and repin it. The locking tab does indeed help keep the connector... well, connected, lol. I would avoid soldering on a new one... it would be a much cleaner repair and more reliable to just replace the connector housing. I also wouldn't try gluing it on or anything.

It's fairly easy to depin the connector with a cheap eBay tool or a homemade one, like a bobby pin, etc. Just slide out the purple locking tab, insert removal tool, pull out wire.

Headlight connector: Clicky Click

Tool: Clicky Click

[Hutch7344]

Ok cool I’ll probably try that. Before I buy those do you think the pins could need cleaning? The used headlight I bought on eBay was from Iowa where they salt the roads and a few of the bolts were kind of rusty. Like I said the old headlight always worked with the broken connector but it’s pretty dry here in Colorado so moisture is rare lol.

[fR3ZNO]

Ok cool I’ll probably try that. Before I buy those do you think the pins could need cleaning? The used headlight I bought on eBay was from Iowa where they salt the roads and a few of the bolts were kind of rusty. Like I said the old headlight always worked with the broken connector but it’s pretty dry here in Colorado so moisture is rare lol.

The pins should be okay since the plug is water resistant. But you can take a look at them when you depin the connector and see what shape they're in.

[Hutch7344]

I’m going to try cleaning the pins today I’ll update the results later. It definitely seems more like an electrical than physical issue since the headlight only cuts out at night. I’ve driven roughly 200 miles the past 5 days during the daytime and haven’t gotten a single “lower headlamp bulb” error pop up no matter how matter times I start the car. But when driving at night, the headlights work on initial startup, then if I stop at a gas station and restart the car I’ll get the “lower headlamp bulb” error, even before the headlight switch is on, and the headlight won’t work. It only ever cuts out after I’ve driven with the headlights on and shut off the car, it’s never turned off during the initial drive no matter how long i drive for. Super weird

[Deerhurst]

HID or halogen? I've had HID bulbs fail and start flickering and random times. One of my plugs has a broken clip too but it's never caused a problem.

Could also be the heat in the system. If HID maybe a failing ballast. Time of day shouldn't matter. At night you will be using your lights. During the day you may not be using them.

I've had similar issues with ballasts that don't like to come back on after being turned off when hot. For me it was a CANBUS issue being too sensitive to the ballast.

[Hutch7344]

Pretty sure it’s halogen I’m not sure what hid is. The two options were xenon and halogen and mine were halogen

- - - Updated - - -

Update: Cleaned the pins on the headlight and it still wouldn’t work unless I was pushing the connector in with pretty considerable force. So I bought the new connector and the wire removal tool as previously suggested. New connector locks in all the way and all looked good so I turned on the headlights, nothing. Still, with the headlights on if I push the connector into the headlight as hard as i can, the headlight works. As soon as I let any pressure off it turns off. Seeing as how the old headlight worked just fine with the broken connector I’m thinking it has to be the pins on the new headlight, just weird that it’ll work I apply pressure. Going to buy another headlight.

[A4SoftWalker]

Pretty sure it’s halogen I’m not sure what hid is. The two options were xenon and halogen and mine were halogen

- - - Updated - - -

Update: Cleaned the pins on the headlight and it still wouldn’t work unless I was pushing the connector in with pretty considerable force. So I bought the new connector and the wire removal tool as previously suggested. New connector locks in all the way and all looked good so I turned on the headlights, nothing. Still, with the headlights on if I push the connector into the headlight as hard as i can, the headlight works. As soon as I let any pressure off it turns off. Seeing as how the old headlight worked just fine with the broken connector I’m thinking it has to be the pins on the new headlight, just weird that it’ll work I apply pressure. Going to buy another headlight.

Thanks for your update. I'll file this away mentally for possible future use.

[shurur9]

There is a silicone ring inside (violet in the pic) the connector to seal it from moisture.
Sometimes that ring gets unseated or rolled and makes it hard to lock the connector in.
It doesn't take much.

You could try removing that ring and see how the connector fits
If the connector fits without the seal, you can try to reseat the seal or just leave the damn thing out.


My connectors are both trash.
I dab a SMALL bit of silicone goop when I slide them on; it works fine.