Both of my headlight housings (2005 Tucson) are melting on what I guess would be the heat sheild at the top of the inner assembly. On the passenger side I actually have about a 1.5" x 1" piece that has fallen off and rattles around inside of the unit. I would like to upgrade to better headlamps anyway as the factory ones are cloudy and simple, but I'm not sure if I may have a bigger problem that would produce that kind of heat.

 

Are you using higher powered (ie brighter) aftermarket bulbs?

 

Maybe. I just bought it used a couple of months ago. Any suggestions? Like I said, I wouldn't mind upgrading the fixtures. The factory headlamps don't really do justice to the vehicle anyway.

 

Aftermarket headlamps do not meet federal requirements. They are basically junk. I'd suggest getting a used pair of originals from a junkyard or eBay.