Headlight troubles

I noticed the other night that I had a burned out right-side headlight. So I bought a new bulb this morning and proceeded to install it.

It was easy enough to remove the headlight assembly - only three bolts, easily to get to, no need to remove the grille or anything else.
Attachment 10549

And then I noticed that the plastic around the center tab was crumbling and falling apart???
Attachment 10550

The left-side housing is intact and solid. Makes me wonder if maybe some kind of fluid (brake fluid or such??) got dripped on there and started eating it away? I doubt there's any way to repair this, so I'll have to start looking for a replacement.

Then I noticed the plug at the light bulb was burned.
Attachment 10551

Attachment 10552

Wow!! Any thoughts on what happened here??
Ed

I would think the wires had some corrosion at the plug causing the melting/burning. I'm not an expert so this is just a guess... I would replace the plug and use some Dielectric grease upon reassembly... e-bay has light assemblies both stock and aftermarket.
Good luck

This isn't an uncommon problem on the Aveo.

Hit the search box in the top right of the page with "headlight connector" and you'll find threads like this one:

Thread: Headlight Harness Potential fire hazard?

Fixed by replacing with a "high heat" waterproof connector replacement.

Also, eg:

Thread: Front Headlight wiring assembly fried, need help!

My entire headlight casing shattered in my boyfriends hand when we just went to change the bulb. The entire thing is crumbled and falling apart and is being held in place by my hood shutting. The local junkyard quoted me $200, and I hung up on them. I'm glad to hear I'm not alone basking in the glory of our plastic Daewoo Aveo's.


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Car-part.com (a network of salvage yards) has them starting at $75 plus shipping.

E-bay has them both stock and aftermarket... aftermarket ones are projectors... has anyone ever used the projectors sold there?
How did the FUNCTION?
Was the light output better or the same?
Are they worth the money?

I had the same problem I just went to local parts store and got two new plugs cut old ones out and attached the new plug no problems since