My headlights keep melting... Can anyone tell me why?
 

I've replaced the 9004 socket in my 91 three times and they all keep melting. It's the ground connection that seems to be burning out, causing my driver side headlight to be very dim (30-50% intesity maybe), and even the whole headlight circuit to shut down (both headlights won't turn on and the daytime running lights relay sounds like a machine gun)...

Does anyone know what this might be?

Some help would be appreciated.

Thanks in advance.

Maybe you have the wrong bulbs?

No, I DEFINATELY have the right bulbs. 9004 bulbs. That's all there is to it.

while this is just a guess, as this sounds like a nightmare to trace down.

1, replace the DRL unit
2. Try either tapping a new ground to the buld ground wire, or cutting the wire and using a new ground from the bulb and cap off the other end. Keep a close eye on it as you test and touch it for heat, if it gets hot quickly, stop all.

I'm pretty sure the DRL unit was the original source of the problem, 'cause the relay kept clicking, but then I took out the fuse, thereby deactivating the system. The problem stopped for a bit, but came back.

I think the wire shorted out and it could be that one of the wires overheated and melted somewhere along the harness, which is making the short re-occur.

I'm hoping that's not it... And I had thought about making a seperate ground, so I'm gonna try it and see if it works.

If I get desperate, I'll send the 2 wires for the low beams and the 2 wires for the high beams to seperate switches... But how ghetto would that be....

Anyways, if this has ever happenned to anyone else, please tell me how you fixed it.