Headlight melts its connector

You're gonna need to replace the starter solinoid and or the starter...

[quote:8f8682eb18="merlin2021"]You're gonna need to replace the starter solinoid and or the starter...[/quote:8f8682eb18]

The solinoid (replaced solinoid) and starter check out.

It's a ford, so there is only one starter wire connected from the ignition to the solinoid on the starter side of the switch. The wiring overall looks good, no crack's, burns or dry rot..My chiltons says to test the resistance on the ballast resitor wire ( note there is not an external ballast resistor).My diagram for the dura spark III shows the wire connected at the ignition and spliced in to the wire that charges the coil.

What color wires am I looking for and do I have to pull the instrument panel to get acces to and test the resistance of this wire ?

You are looking for a red wire, and it must be replaced with the right length and type!

Next time it does that bang the starter relay-it will do that if its sticking even if the S and I small wires are removed it will do the same. Unless the ignition switch power input is shorting to the starting circuit

Check the voltage at the plug....if over 13.8 with engine running, check your voltage regulator, is the bulb at full bright? if not check the ground wire.

Ran the voltage check with a dial volt meter as follows

battery voltage with out car running 12 volts
battery voltage with car ruinning just shy of 15 volts
voltage at light socket on both headlights is just shy of 15 volts

Also checked ground wire with continunity tester and seems good. was the same on all lights.

Assuming voltage regulator is problem, is this something I can replace or do I need to take it in.

Forgot my manners, Thanks for your help

I would try replacing the socket and the bulb the voltage isnt bad, regulator will go up and down 13.8-14.8 not bad...may be a bad bulb, No modifications that might reduce airflow around that light....right?

When I took the bulb out I noticed that when I replaced the plug the first time I used the same bulb and the prongs on that bulb were covered with a substance that looked burnt. Could that have caused it to go out again? Put it all back together with new plug and new bulb and everything works fine for now.

Again thanks for your help, Carm1234

We may never know! But if it has increased the resistance in the curcuit, it will overheat...