Headlight Help!

[esnave09]

The other night, when I went in for work, I found out that one of my headlights wasn't on. Well, went and fiddled around under the hood a little and it turns back on. Over the course of the next few nights it does the same thing, but it starts doing it with the other one too. I finally ended up taking out both bulbs completely and putting them back in, and now the second one works nice and bright all the time, but the first one to stop working still works intermittently. The plug/harness is in nice and tight, but I found some corrosion around where one of the prongs goes into the harness (that's a new one for all the rust issues, right?) and when it does turn on it's not as bright as before, but if I wiggle it a little it will get up to most of the full brightness.

Now here's the odd part: I will park my car and shut off my lights, both of them working. If I come back 5 minutes later and turn on my headlights, sometimes the one (driver's side) will not be on, sometimes it will. Nothing changed except for me closing my door, which I never slam, so I don't know why that would affect it. If I hit the headlight with my hand (easier than popping the hood in between each delivery run) it will turn on but still be dimmer. Does anyone know why this is happening?! I have noticed earlier in the week before I did the full bulb removal that there was a somewhat louder click/switch noise when it would shut off on the driver's side and then the light wouldn't turn on, but like I said it's random.

So basically what I'm asking is this: Should I just plan on replacing the harness itself, or do you think that it's another issue? And how difficult will it be to do myself, with fairly basic understanding of electrical work and big hands for the ridiculously tight spaces? I did a little peeking and it looks like some of the wiring is heat wrapped, so I know that will be fun, but what else should I expect?

 

[sleepwalker]

Before you go too in depth, pull the bulbs out, and pull the "bulb holder" (that's what the dealer called it) off the bulb - it's the black plastic bit that the bulb plugs into, which then plugs into the harness. I had problems just like what you're describing with one of my headlights, and discovered that the inside of that stupid bulb holder was burnt up. 13 bucks and a trip to the dealership later and my headlight's been the same since.

It might not be what's wrong, but it's a quick and easy thing to check and it might save you from digging into wiring.

 

[sneakypete]

Mine has been doing the same thing, just as you described. No rhyme or reason to when it will turn on or off, and sometimes hitting the headlight turns the bulb back on. I think my bulb holder looks burnt up too. I'll try replacing it. Thanks sleepwalker.

 

[esnave09]

I haven't tried to replace my bulb holder, but I did try flipping it around (my bulbs didn't seem to be seated correctly). I will have to do that......well, next time I go home. It sucks not having a Mazda dealer in town. I'll probably just pick one up from RockAuto or something.

 

[esnave09]

This is my headlight harness on the driver's side, and the corrosion that I mentioned. It looks like the corroded side has spread open a little bit, but maybe I'm just crazy.or it was like that maybe? Not the corrosion, obviously, the opening size.

 

[pcb]

That looks to me like it's melted. There is a lot of power going through that connector and if there is a bit of a bad connection it can create a lot of heat. (just like our fan switch,... that's why headlights have relays)

I'd say replace that connector. I'm sure you can find one at a wrecker for a couple dollars..
I would cut the wires off close to the connector and take it with you for reference at the junkyard (or even the dealer). Then cut off the replacement connector with lots of wire to work with. There are a lot of different types of cars that use the same bulbs as our car so there is probably a lot of cars that will have a connector that will work.

It would be best to solder the connector on or it will corrode and create the same issue.

Rockauto has some choices,... they look different but I think only two of the terminals of the connector in your picture are used,... they have a high heat version to deal with the heat that caused your meltdown.

 

[esnave09]

Okay I was wondering about that. Hopefully I can get that done before the weekend if I can get the part. There aren't any Protege's for at least 100 miles in junkyards around here, and P5's are even harder to find.

If I were to get the high temp socket mentioned above, I would have to change bulbs styles though, and wouldn't that mean I'd have to find a different retaining spring, or at least get rid of it (I'd prefer the latter, cuz those things are a b**** to work with)? Would there be wiring complications with it too, or no?

 

[sleepwalker]

I am nearly certain that you can find that socket, with pigtail wires, new at your local parts place. I know the AutoZone I used to work at (0357, Jefferson City, MO) carried a whole lot of different headlight bulb sockets. One of those would probably work perfectly. If you're going the junkyard route, I suggest what pcb suggested, clip off the bad headlight bulb socket from your car and bring it with you to the junkyard. It doesn't *have to* be a socket from a P5 or Protege - doesn't even have to be a Mazda. If you find a vehicle that uses the same socket, you're golden.

The hi-temp socket on the RockAuto site looks like it is for your high-beams. I don't think there's any way to retrofit a 9005 into a housing designed for an H7 that wouldn't involve some plastic fabrication. If you want to get rid of that spring (which I can't blame you, they ARE a pain in the butt to deal with) the best way would be to swap to sedan headlight housings, which use one single bulb (9007, I think) for high beam and low beam. That'll take some re-wiring though.

 

[esnave09]

True true about the parts stores. I could probs check mine and get one when I pick up the bits for putting in my headers Thursday.
But if I had to fabricate anything, I'd more than likely go with some HIDs. I'm hoping to get a set at some point, but that may not be for quite a while.

 

[esnave09]

So I went and picked up what I thought I needed to fix my headlight issue from Advance, and the only light socket that they had doesn't fit, even though online it says it's an exact fit. So now I'm stuck trying to find one from a junkyard, and the only thing they have locally is....well nothing. The closest P5 I can pull from is in freakin Missouri. So looks like I'll have to talk to the dealer, which itself is at least 60 miles away.

And if it comes down to it, I may end up just getting HIDs. Honestly, with the way my car has gone through light bulbs so far, it seems like it's worth it to me. Thoughts?

 

[sonick]

So I went and picked up what I thought I needed to fix my headlight issue from Advance, and the only light socket that they had doesn't fit, even though online it says it's an exact fit. So now I'm stuck trying to find one from a junkyard, and the only thing they have locally is....well nothing. The closest P5 I can pull from is in freakin Missouri. So looks like I'll have to talk to the dealer, which itself is at least 60 miles away.

And if it comes down to it, I may end up just getting HIDs. Honestly, with the way my car has gone through light bulbs so far, it seems like it's worth it to me. Thoughts?

You guys are overthinking it. Just replace the black bulb holder thing ('low beam male').

I bought both the low temp socket and the bulb holder from RockAuto and the socket didn't fit. Replacing only the bulb holder worked 100%. My socket was also corroded like yours but simply replacing the bulb holder fixed everything.