Headlight Switch Plug HOT/Melting - Defender Source
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Old May 14th, 2016, 11:47 AM
Fred Lobster's Avatar
Fred Lobster
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Pete Gerbine, III
1993 110 (#451)
Join Date: Oct 2012
Location: Gladewater, TX
Posts: 137
Headlight Switch Plug HOT/Melting

I've had to replace the headlight switch a few times, on my NAS 110, due to the internals of the switch getting hot and melting some of the plastic components. As a remedy, I installed the ARB relay kit hoping that would save my switch from future failure. Since installing the relay kit, the lights are extremely bright and may need to be adjusted, as I constantly have oncoming traffic flashing me, until I hit my high beams....which are quite impressive.

Anyway, I have since noticed that the headlight switch plug, and wires, are getting extremely hot and causing the rubber plug to melt a bit, to the point of having to twist or hold the plug in an exact position to keep the headlights on while driving at night...

I thought the relays were supposed to eliminate the heat transfer up the wires to save my plug, but I guess that is not the case. Any recommendations?

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Old May 14th, 2016, 12:30 PM
JSBriggs's Avatar
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Jeff Briggs
Antarctic Blue Super Sports Wagon
Site Team
Join Date: Nov 2003
Location: Auburn CA
Posts: 12,195
Something is amiss. It might be a problem in the parking light circuit. Check the connections and grounds for corrosion.


Originally Posted by sonoronos View Post
sheisters gonna sheist
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Old May 14th, 2016, 12:50 PM
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Bruce Bishop
1985 Defender 110
Join Date: Jan 2009
Location: Fair Oaks Ca.
Posts: 71
Sounds like grounding issue to me also. I converted my defender head lights to the relay system. No more heat and very bright head lights. But I have had over heat issues with corroded connections with the early defender. Clean the connections and a little anti corrosion should help.
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