I have an 03 Escape XLT that keeps melting down the driver's side headlight connector cable (especially at the center wire/low beam). It must be when I use the fog lights because I haven't used them in months now and this latest connector has stayed like new. The fog lights were a factory installed option and work only when the low beams are on and turn off if using high beams.

So what can cause the excess heat at the headlight connector that's enough to melt it? I've never changed the fog light bulbs so I haven't looked at them yet but it's possible they were changed during state inspection without me knowing. How do you access the rear of the fog lights so I can check? It looks like some wheel well plastic has to be removed first or hopefully there's an easier way.

Thanks- Jack

 

It's all done from under the vehicle. For a light replacement it's a lengthy job. Not long, but a PITAbecause of the plastic screws that hold the splash gaurds on.

The only thing I could think of is someone may have replaced them with a higher wattage bulb. Not big enough to blow the fuse, but too big for the wiring.

 

Darn- the bulb in the driver's side fog light was the correct one (#898). The cable going to the light looked good too (no bare spots to short out somewhere). The only thing I did see wrong was that the cable to the fog light was hanging loose and not secured to the frame but that shouldn't cause the meltdown either.
Is there an Escape wiring diagram available on this FTE site for reference?
Thanks- Jack

 

Quote:"The only thing I did see wrong was that the cable to the fog light was hanging loose and not secured to the frame but that shouldn't cause the meltdown either."

But, it could. If the headlight wire has to supply ground for itself AND the fog light, the ground wire could be overloaded, causing it to heat up and melt the connector.
Bad grounds can cause current to take the easiest conductor to carry the current, and it doesn't know it should be grounding through the ground wire, and actually could ground going backwards through other components {such as radios or turn signal lights...} powering them up when they are turned off. If you have a missing ground connection, I'd suggest that you tie it down properly.
tom

 

I've had the same problem with my 02 Tribute and I have never figured out the problem. The 3 prong connector is melted and requires periodic replacement. Driver's side only!

 

The cable has a metal clip built into it so you can attach it to something solid and keep it from banging around loose. I don't think it's meant to be a ground but I attached it to metal framing (painted surface tho) so who knows. I'll start using the lights and keep and eye on the headlight connector. I've replaced that connector four times now and started carrying a spare.

I'll have to dig up a wiring diagram somewhere and try to figure it out. Could also be a skimpy design issue where an engineer was trying to save Ford 1/2 cent per car and now tcesni and I end up replacing cable ends every 6 months.

Thankyou - Jack