DIY - S4/GT/GTS Replacement Tail Light Bulb Sockets
09-22-2011, 08:59 PM
#1
Drifting
Thread Starter
DIY - S4/GT/GTS Replacement Tail Light Bulb Sockets
I updated my previous LED brake light mod posting, it now also shows a single filament socket fab.
https://rennlist.com/forums/928/4551...grade-mod.html
Here's the socket fab portions only ....
Used replacement wiring harnesses are hard to find. You can buy new from Porsche, but the cost may be prohibited. Here's an inexpensive solution using low cost sockets for a Nissan Quest that you can still purchase new and easily modify yourself.
The tail light sockets are for:
1993-1995 Mercury Villager, or
1993=1995 Nissan Quest
Any automotive parts store should sell them, however NapaOnline may have the best price (part number 6803296, online price of $11.69). here:
https://www.napaonline.com/Catalog/C...296_0328210865
Napa price is for a package of two harness, which is four sockets. That's enough to do two tail lights.
Here's how to modify them to fit the S4/GT/GTS tail light assembly:
Remove the tubing and connector housing as shown.
With a sharp razor knife like shown, trim the straight tab. The trick is to cut the plastic like cutting slices of bread. Thin slices, not big cuts, working your way along.
Note: The following photos show the before and after plugs side by side.
Now start trimming the tabs that will hold the socket in the lamp assembly. Trim from the side shown, until you get to the dimension shown on the caliper.
Keep going, do the same for the other side. Then, trim them down some more to the width shown here.
Finally, you need to carefully cut the inside edge to achieve this clearance:
Now for the gasket. I'm using 2 mil thick closed-cell foam. They sell this stuff at crafts stores in 8-1/2x11 sheets in various colors. About $1 sheet.
I used a socket to draw the inside diameter. Using scissors, cut the inside, place the gasket on the prepared socket, and cut the outside diameter.
The sockets from come with dual filament sockets, but you can easily convert them to single by purchasing an appropriate can. The cans simply press in place and can easily be removed with a pair of pliers.
I purchased the BA15s socket can from autolumination.com (part number 62-29, $2.49USD each). These just fit the plastic plastic housing without any modification.
Here's the back sides showing the dual and single filament sockets. Notice how both versions have three wires. The single filament socket has two ground wires (brown).
This diagram for the later 928's shows how factory wiring harness routes the ground wires to each bulb socket. Notice how the single filament sockets require two ground wires.
So, the single filament wiring with two ground wires can be added with a single length of 18 gauge stranded wire, with the insulation cover removed on the length (3/4").
The wire is routed through the two holes, while the bare wire is wedged between the plastic housing and the metal can. Make sure you grease (dielectric) the red wire where it slips through the black rubber seal in order to accomodate good movement of the center contact with the bulb.
https://rennlist.com/forums/928/4551...grade-mod.html
Here's the socket fab portions only ....
Used replacement wiring harnesses are hard to find. You can buy new from Porsche, but the cost may be prohibited. Here's an inexpensive solution using low cost sockets for a Nissan Quest that you can still purchase new and easily modify yourself.
The tail light sockets are for:
1993-1995 Mercury Villager, or
1993=1995 Nissan Quest
Any automotive parts store should sell them, however NapaOnline may have the best price (part number 6803296, online price of $11.69). here:
https://www.napaonline.com/Catalog/C...296_0328210865
Napa price is for a package of two harness, which is four sockets. That's enough to do two tail lights.
Here's how to modify them to fit the S4/GT/GTS tail light assembly:
Remove the tubing and connector housing as shown.
With a sharp razor knife like shown, trim the straight tab. The trick is to cut the plastic like cutting slices of bread. Thin slices, not big cuts, working your way along.
Note: The following photos show the before and after plugs side by side.
Now start trimming the tabs that will hold the socket in the lamp assembly. Trim from the side shown, until you get to the dimension shown on the caliper.
Keep going, do the same for the other side. Then, trim them down some more to the width shown here.
Finally, you need to carefully cut the inside edge to achieve this clearance:
Now for the gasket. I'm using 2 mil thick closed-cell foam. They sell this stuff at crafts stores in 8-1/2x11 sheets in various colors. About $1 sheet.
I used a socket to draw the inside diameter. Using scissors, cut the inside, place the gasket on the prepared socket, and cut the outside diameter.
The sockets from come with dual filament sockets, but you can easily convert them to single by purchasing an appropriate can. The cans simply press in place and can easily be removed with a pair of pliers.
I purchased the BA15s socket can from autolumination.com (part number 62-29, $2.49USD each). These just fit the plastic plastic housing without any modification.
Here's the back sides showing the dual and single filament sockets. Notice how both versions have three wires. The single filament socket has two ground wires (brown).
This diagram for the later 928's shows how factory wiring harness routes the ground wires to each bulb socket. Notice how the single filament sockets require two ground wires.
So, the single filament wiring with two ground wires can be added with a single length of 18 gauge stranded wire, with the insulation cover removed on the length (3/4").
The wire is routed through the two holes, while the bare wire is wedged between the plastic housing and the metal can. Make sure you grease (dielectric) the red wire where it slips through the black rubber seal in order to accomodate good movement of the center contact with the bulb.
