Help identify a loose cable

[pyiap]

I was driving down the interstate and started hearing some metal scraping noise from the driver side rear wheel tire area. Before I could find a safe place to pull over it had stopped but I found this plug loose. Where is it supposed to attach to? I drive an 04 s tip



Here is a location of where the wire ends.



Thanks!

[BYprodriver]

I think that is for the Litronic headlight self leveling, sensor is bolted to the black steel crossmember just past the rear of the driver's side of the engine. The right rear controlarm has a link that goes up to it. The link may have come loose & made the noise & it may have broken off causeing the noise to stop.

[pyiap]

That makes sense, I took it in for service a week ago and notices my high beams didn't rise when I turned them on. I'm assuming that if the control arm broke off then it needs to be replaced? Any negatives if I don't replace it besides not having my headlight self level? Also thanks for the quick reply.

[thom4782]

I think BYprodriver is right. My Litronics weren't tilting and I found out that the plug wasn't connected to the headlight assembly.

If it's a loose plug up front at the headlight, the fix was simple. I pulled out both headlights and found the one where the plug was disconnected. I reached inside the headlight opening in the fender behind the headlight tray and found the loose cable. I pulled gently on the cable until I had the plug in hand. I reconnected the plug to the headlight assemble and put back in its place in the fender. Voila, the headlights tilt once more.

I'm not sure what the fix is if the plug is for an angle sensor in the front or rear ends. If an angle sensor has broken off, the manual directions say its easy to reinstall. The bad news is that the manual also says one needs to use PST2 to recalibrate the system after the install and then also readjust the headlights. Sounds like a dealer fix is in order. Probably parts and 1 hour or so of labor.

The tilting is supposed to keep the low beams positioned when accelerating or decelerating. They position is supposed to keep the Litronics from causing glare for oncoming drivers. I drove around without mine tilting for a year or more before I noticed they weren't tilting. So other than the effects on other drivers, I don't think you'll harm your car.

[pyiap]

Thanks all for the info. It does look like the rear sensor completely snapped off and is laying somewhere on I5, bummer. I'm wondering what would have made it come loose? I was driving 25 in the middle of traffic when it fell off and it looks like a piece that would be bolted on.

I believe it was this piece that broke off. The right side of the cross beam pretty much sheared off.

[BYprodriver]

Originally Posted by pyiap

That makes sense, I took it in for service a week ago and notices my high beams didn't rise when I turned them on. I'm assuming that if the control arm broke off then it needs to be replaced? Any negatives if I don't replace it besides not having my headlight self level? Also thanks for the quick reply.

The control arm is a critical suspension part, if it broke the car would be undrivable. the self-leveling link attaches to the right-rear control arm by a little plastic part that is very fragile. About $5 for a new 1. So if you remove the RR wheel you can see the linkage, plug the electrical lead back where it goes & see if you need to replace any parts besides the plastic part. If you go to the dealer 1st & just buy the plastic part & ask them to give you a printout of the parts diagram it will show you all the parts & where they go. Should be able to replace the parts yourself & test lights to see if you need to have them aligned, I never have.

[BYprodriver]

Originally Posted by pyiap

Thanks all for the info. It does look like the rear sensor completely snapped off and is laying somewhere on I5, bummer. I'm wondering what would have made it come loose? I was driving 25 in the middle of traffic when it fell off and it looks like a piece that would be bolted on.

I believe it was this piece that broke off. The right side of the cross beam pretty much sheared off.

OK there it is, looks like the plastic piece at far left side of the pic. Also looks like the sensor has junkyard markings on it like the part has been replaced before. The sensor bolts to the steel crossmember so either that huge bolt fell out or part of the sensor broke off.

[thom4782]

This is a picture from the Porsche repair manual. I can't tell, but does it look like the area you think the part fell from. If so, I can summarize what the shop manual suggests doing.

[thom4782]

This time with the picture4

[pyiap]

Thanks for the diagram Thom. Would you happen to have a part number at all?

Here's a better photo. The arm sheared off where the red arrow is and I was to sort of read the tiny part number on it. But it doesn't come any searches.

996 331 376 01

[WhipE350]

Originally Posted by pyiap

...I took it in for service a week ago and notices my high beams didn't rise when I turned them on.

What was the service for? Were you have trouble with the lights leveling before you brought it in.

[pyiap]

Originally Posted by WhipE350

What was the service for? Were you have trouble with the lights leveling before you brought it in.

IMS retrofit, AOS, Water Pump, and major maintenance. All were preventative and there was nothing wrong with the leveling before I brought it in.

[WhipE350]

Something seems fishy here. A LOT of stuff is taken off the car during the maintenance you referenced. Not trying to start an issue with you and your repair shop but it just seems strange. The pictures you showed would require a lot of vibrations or impact to break. I know when I took my transmission out for my IMS and clutch that the drive shafts are moved all over the place and they could easily break something like the leveling.

[pyiap]

Yea I was kinda thinking the same thing. The piece seems pretty firmly bolted on in the diagram. But I really can't prove anything.

[thom4782]

You can find the diagram, the parts and their numbers on pages 119 and 120 of the parts Katalog. One can download the catalog at http://www.porsche.com/all/media/pdf/originalparts/usa/986_USA_KATALOG.pdf. Hope this helps.