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Old Oct 21, 2019 | 06:03 PM
  #1  
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Default Headlight Hell

So I don't often check my tail / license plate / etc lights (who does?). But I have been recently. I noticed the running light on the left side was out, so I bought some bulbs.

While playing with the headlight switch, that same light came on when the headlights were not on. When the headlights were on, the running light was out. Then I noticed that the headlight switch assembly had a slight extra notch just past the headlights coming on. That notch had the effect of cutting out the left side running light.

So I get a new headlight switch assembly (non-OEM) since the bulb is clearly OK and put it in. Now the rear tail lights work but the front left headlight is out. WTF?? Coincidence I suppose but the H7 bulb was actually burned out. So off to the store I go to get a bulb.

When I opened the assembly, I noticed the wires were no longer covered by the plastic, so I heat shrink both sides .. and replace both bulbs.


Of course I break one of the ear off of this piece while doing it:

But I've now got everything in.

Problem is now one headlight (left side) seems brighter than the other. AND my rear right fog light doesn't work.

I feel like I am chasing my own tail.

Is this all just coincidence or am I just being a dope?

PS - Does anyone have the part number for that plastic piece above?
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Old Oct 21, 2019 | 07:25 PM
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The insulation has dried out due to heat and cracked. I would check all the affected wires and where they terminate into any molded plugs. The pressed crimps will loosen up over time due to the heat/cool cycles.
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Old Oct 21, 2019 | 08:42 PM
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Default Insulation

All the insulation in both headlights on my 99 996 were dried out and cracked. Replaced all the wiring. Daunting process.
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Old Oct 22, 2019 | 09:37 AM
  #4  
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There is no right rear fog light, only left rear fog light.
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Old Oct 22, 2019 | 10:30 AM
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Get a multi-meter and check the amps between the two headlight. The rear only has one fog light.
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Old Oct 22, 2019 | 10:49 AM
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Doesn’t the “extra” notch activate the TUV required parking light that is turn signal stalk controlled? IE parked engine off, lights off, switch to “notch” stalk to left turn left lights on ...etc.
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Old Oct 22, 2019 | 12:35 PM
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Originally Posted by hi8ha
All the insulation in both headlights on my 99 996 were dried out and cracked. Replaced all the wiring. Daunting process.
I cut the wires in the middle, put heat shrink on, soldered them back together and shrunk the heat shrink tubing. It was actually very easy when you have all the tools.
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Old Oct 22, 2019 | 12:37 PM
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Originally Posted by Imo000
Get a multi-meter and check the amps between the two headlight. The rear only has one fog light.
Somewhere in the recesses of my brain I had heard that the rear fog lights were on one side only. Thanks for reminding me. Saved me buying another headlight control switch!!
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Old Oct 22, 2019 | 03:34 PM
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I was curious what the inside of the old headlight switch looked like. I'm not sure but I think I may have broken it. lol
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Old Oct 22, 2019 | 03:54 PM
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That'll buff out!
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