Headlight connector terminal tool

[ovul82jazz]

The saga begins with me changing my headlight bulb in my '01 'Box last Fall when it was pretty cold out. When I put the headlight cassette back in, the flange on the headlight connector (the blue thing with the orange weather stripping) snapped. I sourced the part - not an expensive piece - but none of my "normal" terminal tools seem to be helping me ease out the wires to change out the terminal.

I don't want to get too aggressive with it until I have a better clue what I'm doing and the service manual that I have is no help on this one.

Does anyone have any insight into how to do this seemingly easy task, or does the answer begin with "porsche special tool"?

The "season" has finally arrived and I'm anxious to get my car back on the road.
:dance:

[ovul82jazz]

So, its been a painful couple of days and digging out the answer to this question was so challenging that I thought that I would reply to my original post just to make sure that the info was available to everyone else out there in boxterland.

The tool that performs this particular operation is Porsche tool number 87050. A company called Sir Tools used to make a far cheaper version (part number st9701)for folks like me who might use the thing less frequently. It was not apparently a big seller and it was discontinued. That's the bad news... the good news is that Sir Tools incorporated the terminal wire extractor into a "kit" .. (part number st 9025 and one is now winging its way to Saskatoon and I should be able to get my car back together.

So, thanks to Boyd at Sir Tools (www.sirtools.com) .. he was really helpful. I've attached a couple of pics so that anyone else will have some visuals and won't have to scale quite the learning curve that I did.

all the best,

[Nitro]

Originally Posted by ovul82jazz

The saga begins with me changing my headlight bulb in my '01 'Box last Fall when it was pretty cold out. When I put the headlight cassette back in, the flange on the headlight connector (the blue thing with the orange weather stripping) snapped. I sourced the part - not an expensive piece - but none of my "normal" terminal tools seem to be helping me ease out the wires to change out the terminal.

Where did you find the part? I am having the same issue and unfortunately don't know where to get a replacement.

Any help would be greatly appreciated.

Thanks.

[ovul82jazz]

Hi Nitro,

I just called the Porsche dealer in the nearest city that had one - which in my case was Edmonton. They ordered it in and shipped it to me on the bus. Its only a $25 part - was I ever surprised about that.

My guess is that the dealer in Minneapolis would be able to get it for you with little or no difficulty at all.

best,

Roger