OK, here's one I haven't seem on this forum. I have a 1996 Protege ES, 1.8L, automatic. 192,000 miles, all original, right down to the radio. I have always used exact replacement headlight lamps. Every year I melt the headlight plugs. Whenever I go to a junkyard, I grab plugs off the boneyard cars and splice them in, so I have a box of spares, but I'm getting sick of doing this job. I've seen other cars driving around with headlights half on, so I know I'm not the only one with this problem. Has anyone come up with a permanent fix for this problem?

BTW, what the heck is a Toyota ad doing on a Mazda website, oh yeah, Ford is broke!!

 

There has got to be a bad connection in there somewhere causing the lamp to draw too much current through the wiring. I suggest you trace everything back as far as you can go and see if something has been damaged or has corrosion started on it... like a ground wire.
Short of that, add a second ground to that HL and see if that solves the issue.