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New Headlight Won't Mate With Truck Connector

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The continuing saga of my headlight woes. The new headlight (same part number of the previous one that wouldn't adjust) won't allow the car cable connector to go in far enough to lock. I know what happens when it doesn't get locked.

There is a little piece of white plastic about the size of a paper match but thinner sticking up inside the flat end of the light connector shell that my other headlight doesn't have. As best I can tell it is hitting the actual pink/purple connector body and stopping the connector from mating. I have tried to push it in and pull it out to no avail. If I had to guess I would say it is a part of the headlight assembly that was supposed to go on the other side of that wall but wasn't properly aligned when the back of the headlight was put on. I really don't want to have to reinstall the old headlight and send this one back to get another one that I can install so I can have a proper headlight and a box to send the first one back in but I don't see an alternative.

Am I missing something?

Thanks,

Al
 
Pic?
There are lamps and sockets that have similar numbers that look almost identical EXCEPT for a “tab” inside the socket that must line up in a groove. Like these that are on some Avengers we have at work. One’s for high beam and the other low beam. One’s a 9005 and the other is a 9006.

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Pic?
There are lamps and sockets that have similar numbers that look almost identical EXCEPT for a “tab” inside the socket that must line up in a groove. Like these that are on some Avengers we have at work. One’s for high beam and the other low beam. One’s a 9005 and the other is a 9006.

View attachment 131621 View attachment 131622

Thanks Scott, but that is not what this one is. I have the projector headlights. There is only one connector and it is common between the projector halogens and the HIDs. The picture is of the connector on a simiilar "normal" headlight. On the replacement headlight there is a piece of white plastic strip which is not a part of the molded connector between the recessed contact carrier and the connector shell at the top of the picture. I can stick a probe between the strip and the connector shell and it will bend toward the contact carrier. I should add that the headlight I am replacing is defective because it will not adjust. It replaced a leaky original headlight. The two replacement headlights are the same part number from the same manufacturer.

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The headlight, a REPD100168, would not mate with my wiring harness. I thought the problem was a little piece of white plastic that didn't look like it belonged there at the end of the headlight connector where the mating connector shell is flat. I scored it and twisted it out but that wasn't the problem, the connectors still wouldn't mate.

The actual problem was the manufacturer used the wrong connector shell on the headlight. The shell of the headlight connector was too tall and was bottoming out on the orange weather seal gasket deep inside the truck connector. I confirmed this by measuring the distance from the front of the truck connector shell to the weather seal and from the electrical connector surface to the top of the shell of the headlight connector. I cut off about 3/16" of the headlight connector shell and now the connectors mate and lock.

This was WAY harder than it should have been, but the good news is the seller refunded my money and told me I could keep the headlight. After about 3 hours of messing with it, it works. For a $300 headlight, I guess I got paid about $100 an hour, lol.
 
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