Headlight plug w/all the wires coming of it continue to over heat and light blinks off and on. 1993 ford truck F350.I have replaced it twice and I have replaced several switches also each time the plastic housing where 1of the wires is in starts to melt,this is when the head lights start flashing off and on.

Do you have glass sealed beam headlamps or plastic aero headlamps with removeable bulbs?

Is it the connector on the headlamp that gets hot?

Before you do anything else, check the ground strap from teh engine to the body. If broken, loose or corroded, excessive current draw can occur.



For example, a loose ground strap between the engine and body dash panel may cause an intermittent operation of the lamps and gauges. Inspect and tighten, if necessary, the ground strap attaching screws at the back of the engine and the body dash panel. If a No. 10 screw is required, Use Part No. 42367-S36 hex washer head tapping screw.
NOTE: Any screws or bolts used for attaching the engine-to-body ground strap must have an "S36" finish (zinc plate plus dichromate dip). Do you have glass sealed beam headlamps or plastic aero headlamps with removeable bulbs?
Is it the connector on the headlamp that gets hot?
Before you do anything else, check the ground strap from teh engine to the body. If broken, loose or corroded, excessive current draw can occur.

For example, a loose ground strap between the engine and body dash panel may cause an intermittent operation of the lamps and gauges. Inspect and tighten, if necessary, the ground strap attaching screws at the back of the engine and the body dash panel. If a No. 10 screw is required, Use Part No. 42367-S36 hex washer head tapping screw. NOTE: Any screws or bolts used for attaching the engine-to-body ground strap must have an "S36" finish (zinc plate plus dichromate dip).