Lost both headlights and high beams

[Cheese Monkey]

Don't know where they gone

Sidelights fine.

Look to be individually fused?

In Italy right now - lots of tunnels

[the dutch guy]

Check the relays as well as the fuses. Do the small 5w lights in the headlights still work?

[Cheese Monkey]

Started with the obvious. Checked the lamps- fine. Turned out the common wires were loose on the lamp pin and the resulting poor connection has made a load of heat. This has completely melted a lot of the wire and most of the connector block. Crimped them back on with some pliers for now! And gaffa taped the wires

Just a bloody coincidence they both fail at exactly the same time making me stressed thinking its got to be complicated

[ake]

Started with the obvious. Checked the lamps- fine. Turned out the common wires were loose on the lamp pin and the resulting poor connection has made a load of heat. This has completely melted a lot of the wire and most of the connector block. Crimped them back on with some pliers for now! And gaffa taped the wires

Just a bloody coincidence they both fail at exactly the same time making me stressed thinking its got to be complicated

You probably had already lost one and not noticed.

[Cheese Monkey]

Maybe within 20min of each other cus I walked round the van before I left this morning!

[Cheese Monkey]

In S. France now and lost the o/s one. Well it went very dim. Opened it up again and pulled the connector clean off the wire

Bulb had melted the rubber around the pin so that was wobbling and knackered. New bulb and wrapped the remaining wire around the pin and taped it on. Driving overnight tonight for Calais ferry in morning so fingers crossed they hold out til morning

Can you get a new sub loom for the headlight assembly? Or will I just have to solder on new lamp connectors?

[the dutch guy]

Use a proper crimp tool. Do not solder connections in the headlight, they get too hot and the solder weakens over time. Use a racheting crimp tool and proper sized AMP connectors.

[Cheese Monkey]

That's an good point indeed. I have some bloody expensive crimp tools for work so that's no bother!

[the dutch guy]

Cherry on top is putting heat shrink over the connections to prevent them from getting loose.

[Cheese Monkey]

Yeah I'd do that anyway