The brown wire is the ground wire, and this sounds like either 1) your wires are corroded, or 2) someone put in a higher wattage bulb on the high beam.

That connector on the low beam is a standard 9004 connector (if you are dealing with DOT headlights) or H4 (if dealing with EuroSpec headlights.)

<http://www.amazon.com/Headlight-Connector-Socket-Harness-Moisture/dp/B002MVETKM>

On May 16, 2012, at 12:36 AM, David Klein wrote:

> Here is follow up on this issue.
>
> Will help from the list I have looked at the headlight bulb socket
> connections and see that the brown wire coming from the high beam plug
> is melted at the low beam bulb plug.
>
> How do I fix this connection. I looked at a couple of venders but
> don't see any new bulb sockets for sale. Is this junk hard thing or if
> I find the right electrical connector so I can cut the wire and
> connect it directly with new couple?
>
> TIA, David
>
>
>
>
> On Apr 26, 2012, at 6:23 PM, David Klein wrote:
>
>> Hi All,
>>
>> I am having issues with my head lights. I have the Go Westy
>> headlight upgrade and it is wired as per instructions except the
>> power wire was wired straight to the battery b/c german mechanic
>> didn't want to send it through the wiring harness connection.
>>
>> I have had ground issues under the dash in the past and just
>> finished making sure all grounds are good.
>>
>> my current issue is:
>>
>> on low beam:
>>
>> drivers side lights  low and high bulbs are both on but noticeable
>> dim.
>> passenger side light low bulb on with normal light lever and high
>> beam bulb not on.
>>
>> on high beam
>>
>> drivers side high bulb on and normal power and low beam bulb not on.
>> passengers side lights both on at normal light levels.
>>
>> When switching to low beam the passenger stays on for a second after
>> switching form high to low. I hear the relay click then passenger
>> lights turns from high to low beam mode.
>>
>> I hope this makes sense and please ask questions if anything isn't
>> clear as mud. Is this still a ground or relay issue or??
>>
>> Thanks in advance,
>>
>> David
>>