Automotive Electrical Components: HELP!!!!!!

DAP · Jun 28, 2004

A couple a years ago, I bit the bullet and bought a 400 USD pair of dual beam off road/driving lights for my pickup.

Despite this post, they are quality items. They take a 90/130 watt H4 bulb. Obviously, at that wattage, they need a proprietary harness, which you get with them.

This winter, a light went out. I replaced the bulb but that didn't work strangely. I called the vendor (WARN, the winch guys) and they were outstanding.

I replaced the relays (my dime). No dice.
I replaced the fuses (my dime). No dice.

I replaced the switch (their dime). No dice.
I replaced the entire harness (their dime). No dice.

All outta warranty too.

Finally, I took a look at the light housing itself. The 3 prong male plug is toast. This is a sub-harness that has a 3 prong male on one end and 3 prong female on the other that connects to the harness. This sub-harness is toast.

At the very least, I must replace the male connector. Worse case scenario, I must replace the entire wire and ends.

I'm loathe to ask the vendor for another freebie as they have went way above and beyond the call of duty. But if its all I've got, then I will. This wire and connectors are installed when the light housing is built, so I would have to do some splicing of factory parts. They may simple refuse to supply this because of that whether I pay or not.

Anyway, I need a resource to locate one of these 3 pronged male connectors for an H4 class bulb.

Anyone got any ideas? The NAPA and other autoparts store just scratch their heads.

Attached is a pic of the cutway of the light.

<gulp>

BillyP · Jun 28, 2004

Why not call Warn and ask to buy the male connectors from them /forums/images/graemlins/confused.gif

If they don't have just the male connectors for sale, they can surely give you a source.

DAP · Jun 28, 2004

I figured I give the crew here a shot. Obviously, as I said above, I'll call them. They may infact make be buy the whole damned housing though.

BobReeves · Jun 28, 2004

Might try a junk yard, if it is anything like the plug on late model head lights.

TWINKLE_TOES · Jun 28, 2004

Check Here

polecat · Jun 28, 2004

will b back 2 this one but really gotta go right now!!

Soundguy · Jun 28, 2004

Is this something that you can't 'rig' with a spade connector? I've seen a small medium ( normal size we see around the stores ) and a large.

Seems to me it should work if the light has male ends like some of the other H series bulbs.. If round posts.. try a molex type connector... Radio shack sells various sizes of molded harness.. usually flat style though.. however the female metal inserts are included. You could us that and solder up some hookup wires.. etc.. and then build up the bamaged plug with an epoxy stick.

Too bad you don't have a VOM.. could have saved you some money on the relay and the fuse.. and some time getting / replacing another switch and harness.

Soundguy

DAP · Jun 28, 2004

Yea, I should have a meter at this stage in my life, but it goes at the bottom of a long list.

Even though they replaced the harness, as it turns out it was unnecessary.

I thought about jury rigging this with my solder gun, but that would mean soldering directly to the bulb .. a Darwin award when the bulb goes.

Plus ... I'm not altogether sure just how suitable the wiring on that sub harness is at this point. I took the connector apart and tried to clean the brass conductor clips but they were scorched too badly. I need either the H4 type connector and/or new wiring. There's a proprietary (I think) connector on the other end to that plugs into the harness. That connect looks ok, but I won't know till I solve the male connector at the bulb.

Remember, these lights are 90/130 actual wattage. Not 55/60 bright whites that look like 90/130 as the boxes for OEM bulbs repeat.

And you're right, the bulb does have spade shaped posts, 3 of em ... If I new where to get these females for these spades, I could clean up the existing plastic plug and go from there.

Radio shack didn't have em, neither did the auto parts joints.

Still looking ....