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Hi, the connector plugs for the headlights have become brittle with time and heat with pieces breaking off meaning the plugs will no longer seat properly.
I sourced some new connectors and a tool for removing the leads thinking it would be a relatively simple job. Not so. I cannot remove the wires from the old fitting and am afraid if I pull too hard on the wires they will come away from the plugs on the end.
Has anyone successfully changed these out and if so please share how you did it?
TIA
Greg
new plugs on the left - tool for removing wires on right
Did you check to see if there is a locking mechanism for the pins in addition to the spring tabs on the contact itself? I have not worked on this specific connector but I have worked on other automotive connectors and some have a locking mechanism that is snapped into place after all the wire contacts are seated in place. To remove the wires you have to slide the locking mechanism out and then use the connector tools to pull the wire and attached contact out. The pink part seen in the housing in the middle of your picture might be part of a locking mechanism.
Since you will be discarding the old plastic housing anyway, can you simply cut it apart with a rotary Tool (moto-tool) to release the pins? Harbor Freight make a $10 moto-tool that would work great for this: Drill Master Rotary Tool Kit 80 Pc
Mine were brittle and cracked so I cut the connector off and made my own harness with quality connectors. Now if I want to take out the housing I just pop it out and disconnect the wiring harness. So much easier than sticking with stock set up
Since you will be discarding the old plastic housing anyway, can you simply cut it apart with a rotary Tool (moto-tool) to release the pins? Harbor Freight make a $10 moto-tool that would work great for this: Drill Master Rotary Tool Kit 80 Pc
Give the man a prize. I have a dremel, problem solved. Is this place great or what?
Update: Didn't need the dremel. The little red bits are a locking mechanism. Once unlocked the pins are easily removed with a terminal tool and a little gentle persuasion.
Glad that worked out for you. As geoloab noted in the thread I linked above, "Unlock the two red tabs on the plug facia, and introduce the porsche terminal removal tool to flatten the two whiskers holding the metal terminal." https://rennlist.com/forums/993-foru...sassembly.html
Thanks Foxman, I should have looked a bit closer at that post, when I saw 'Unclip the white housing and slide it back' I didn't understand and thought the rest may be irrelevant.
08-08-2018, 09:57 PM
Headlight plug - how to replace?
