wwwdrew

Had this repair done per NHTSA Recall#14V-177 back in 2014. The dealer replaced both lamp carriers (204-820-15-00 & 204-820-16-00), contact bushing x2 (013-545-76-26), and plug x2 (211-545-03-28). Now in 2019 with 110k miles the brown wire melted the connector and one of the lamp carriers, and back lights fail intermittently. Does anyone know how to remove the contact bushing from the connector plug, or do I need to buy 7 bushings and cut the 7 wires from the melted plug and re-crimp to the new plug?

09/12/19 Update: For whatever it's worth, I did buy 7 bushings and cut the 7 wires from the melted plug and re-crimped to the new plug. It has worked so far!

Ellen Higgins

75,000 mi, 2008- never saw a recall on this til the problem came up. The car has finally gotten the air bag recall taken care of so I don’t have to be worried about being impaled by shrapnel in my own car anymore, now no rear right lights with brown connected insulation melted, scorch marks both sides of panel into which is inserted. Noticed the problem when 2 light bulb change in a day didn’t do it. I was wondering where that smell of metal and plastic burning was coming from. Now it’s at the dealer and they tell me the recall has ended. From what I read here sounds as tho I’m better off doing my own repair.

benzdude

Recall repairs never expire as far as I know.

All they need to do is give you replacement bulb trays/holders for both sides. That's what i got for my recall.

Also, After 3 years of waiting they finally got the air bags????? I got tired of waiting and sold my car.

wwwdrew

For whatever it's worth, I did buy 7 bushings and cut the 7 wires from the melted plug and re-crimped to the new plug. It has worked so far!

benzdude

But did you fix the insufficient grounding issue which causes the burning?

wwwdrew

But did you fix the insufficient grounding issue which causes the burning?

Unfortunately I didn't. But hoping it takes the remaining lifetime of the car before it reoccurs. I also told my wife to stop turning lights on during the day (she didn't realize she had the daytime running lights). Interestingly the front right and left parking lamp bulbs run too hot too and melt the headlight housing (documented in other posts). I found lower wattage bulbs to hopefully avoid further melting (along with now not running daytime running lights). Other than these issues it really is a solid car with 117k miles (knock on wood)

Fisz

It's just a temporary fix. I've added an additional grounding cable, which is soldered directly on the bulb housing to the circuit, and connected it to the car body.