Tail Light Bulb Melts Housing!

[Steve_in_Florida]

1992 FJ 1200 ABS.

I noticed that I had only one tail light and no brake lights.

Opened up the rear to change bulbs, and found that one was completely black, and had melted down into the light housing by about an inch.

Hmmm.

Swapped out the entire pigtail, as the bulb holder was a bit melted, also. Looks like I'll have to replace the taillight housing to make the proper fix.

Was expecting to disassemble the rear ANYWAY, as I have some newly powder coated grab handles to fit.


What would cause this to happen? Standard bulbs don't seem to last long, anyway. Vibration? Charging system? Solar flares?

Steve

[aviationfred]

Without any photos of the affected parts/wiring. Here is my stab....

3 wires go to the tail light connector, within the tail light housing those wires split and go to each of the 2 bulb sockets. Only 1 bulb is affected according to your post. And the wiring to and from each connector half is not charred, discolored, or hardened.

I will say the source of the problem is 1 of 3 things, all of which is inside the tail light assembly.

1, the bulb used has a higher wattage rating than OEM spcs.
2. the socket failed.
3. the wiring from the connector to the socket is damaged.

Fred

[FJ1100mjk]

Pisser. I've been plagued by short life on the tail lights too. Even known brand ones will puke. Even those seemed to be manufactured in China.

You might have a high system/charging voltage, and that wiil cause bulbs to die quicker.

Recently bought these

http://store.candlepower.com/roseandloli.html

And these

http://store.candlepower.com/11subrhi2bu.html

To try out, but haven't had the opportunity yet. Hope to have better luck with either, or both.

[Charlie-brm]

Monday morning quarterback suggestions:
It could be the spring in the socket was worn out and not keeping enough pressure on the tip contacts; so they had mini arcs or at least some corrosion invading the microscopic gaps.
Either one will mess with the contact surface condition, reducing the effective area that is still conducting. When that happens, things tend to heat up trying to get the current across the connection to the bulb or anything else drawing a load. Vicious cycle to destruction.
Here's a voltage regulator plug that fried up from neglect:




Now that you've replaced the socket, hopefully you feel a good firm "push back" when you insert the bulb. I'd apply dielectric grease while you have it accessible.

[Pat Conlon]

I think Charlie is right. Loose contacts causing arching and the melting of the connector.
The same thing happened to me on my headlight plug on the way to the central rally last year.

If you were overcharging you would have other symptoms.

[rktmanfj]

Was it the right hand bulb, by chance?   

[Steve_in_Florida]

Randy,
Yep. Right-hand.

One bulb seemed brighter, the last time I checked. I suppose that I could have installed the incorrect wattage. Interestingly, the tips of the locks were all chewed up. Gone on one side. Just a little hole.

I'd provide pictures, but don't know where to take my film anymore.

Steve

Was it the right hand bulb, by chance?   

[ct7088]

The little bayonets that hold the bulb in place are at different heights forcing the bulb to be oriented in the proper direction. With one missing the bulb may have been in 180 degrees making the brake light filament work as the normal tail light. This would both pull more current and reduce the spring tension of the contacts.
Chris

[ct7088]

I do have a extra tail light that I got from FJScott if you need one. Cost of shipping only. Got a UPS account?
Chris

[rktmanfj]

Was it the right hand bulb, by chance?   

Randy,
Yep. Right-hand.

One bulb seemed brighter, the last time I checked. I suppose that I could have installed the incorrect wattage. Interestingly, the tips of the locks were all chewed up. Gone on one side. Just a little hole.

I'd provide pictures, but don't know where to take my film anymore.

Steve

And I figured it was because you were out of gunpowder for the flash... 
I ask, because in all these years, my '89 still wears the OEM left bulb, but the right one has been replaced several times. 

I've asked this question several times, and it's always the right one.  Go figure.

[Pat Conlon]

Re: Right side burn out
I *could* make a political joke at this point, but I won't.... It's the wrong section anyway....

[Steve_in_Florida]

Chris,
I think you nailed this one.

Evidence points to me installing the bulb incorrectly, shearing off the locking ears. The fact that one bulb was clearly brighter than the other also supports this conclusion.

How could I have done that!??!

I've had to change the bulbs out on the road before. Once, after a spirited back-road ride to the beach, someone pulled up next to me at a traffic light, and pointed out that I had absolutely *NO* rear lights at all!

Thank you for the offer for the tail light housing. I think I already have a spare in my stock.

Steve - The guy who NEVER makes mistakes, and is really good at parking. (Right, Pat?)   

[Pat Conlon]

Yea, that was a close one.....Sorry about your mirror.

We never did find a stripper did we?