This is not on my truck, but on my '02 Focus ZX5...
A while back (not knowing what damage they can do) I put in higher wattage headlight bulbs in the Focus. A while later we had some issues with them flickering on and off so I investigated and found a burnt headlight relay as well as melted headlight connectors and even some of the plastic around the relay on the fuse panel was melted also.
So I put some stock wattage bulbs back in, and soldered new connectors for the bulbs and at the same time I put in a new relay.
My fiance called me today at work to tell me her car had no headlights, then they flickered on and all was well.
I got home from work, and sure enough that same relay is burnt again. It's probably been close to a year since I changed the last one.
Could there still be some issue still in there, or does a relay short out when it's done and turn a burnt colour on the sides/melt a bit at the base?
For now I just pulled the fog light relay and put it into the headlight spot so she has lights to go to work tomorrow morning while I get a new relay at work (and a second for the glovebox spare!)
2011 Mazda3 Sport GT-E - 18" Rage wheels/Mazdaspeed3 Exhaust - mostly stock... for now!
1968 Ford Mustang - 5.0L EFI/T5 trans/8.8LS axle/4 wheel disc - under construction!
SOLD! 2007 Ranger FX4 Level II - Superlift/15X10" Nomads/33" Duratracs
2005 Chevrolet Colorado - 391,000km and counting...