My low beam headlight connector melted and I can't find a 3 wire connection. I tried the 2 wire but that melted within 5 min. It's a 2007 s40i.I would upload a picture but I can't figure it out on my phone...

 

did you search some of the dealer parts sites like volvopartswarehouse.com or tascaparts.com for a new wire harness? That will help you get the OEM part number to search on.

 

I think I might have found one today. It appears to look like my current 3 wire connection but idk for sure. Do you know why the 2 wire one wouldn't have worked if that's all any auto parts store has?

 

Why is a headlight connection melting? What type headlights do you have?

 

I'm not sure what is causing the melting. The lights are the low beams that are listed in my manual. The new one I bought is identical to the one being replaced. And actually the bulbs aren't burning out, they just die from the melted connection.

 

resistance = heat, so check for corrosion, contamination on the contacts etc...