Boxster headlamp assembly internal wiring

[dghii]

2000 Box S with Litronics.

I had previously replaced my parking lights with LEDs, which matched my litronics nicely.

Went to swap out the fogs with H7 LEDs. Swapped with no problem but after swap, noticed that the pass. side parking light was out. I pulled assembly out to check the bulb and found that the insulation on mutiple wires was dried, cracked and missing! No wiring looked burned, just looked like the insulation had dried out and cracked away.

Anyone ever have this happen? I haven't pulled the drivers side to take a look...kind of want to leave it alone! Will post pics.

[dghii]

[dghii]

Apologize for the pic size and double images. Been a while since I posted pics and I know (now) what I did wrong.

[ppbon]

... on most German headlights that are 10 years old or older.
Same issue in Mercedes Benz, Audi, VW.
Put some electrical tape on the frayed naked wires otherwise you will start blowing fuses and damaging the lights switch.
Happy Boxstering
Pedro

[particlewave]

Yep.
75% of all the headlights that I work on need all of the wiring replaced. I hate it. So much.

Be careful with the fog lights. If the insulation is brittle and falls away when you move the connector, it's very difficult to get to without opening the headlight.

[lkchris]

New German regulations from mid-1990s-on require biodegradable wiring harnesses.

[lkchris]

Osram® All-Season® Selective-Yellow Tint H7 55w Bulb

[dghii]

I'd just never seen this pop up of the forums before. I used liquid electrical tape but plan to go in and replace the damaged wiring.

[professorman]

Anyone else repaired this? I am thinking either liquid electrical tape or heat shrink tubing. Thoughts?

[spinjockey]

You can buy remade wiring harnesses

https://www.adriantaillights.com/store

[Hasdrubal]

I pulled the harness completely out of both sides and crimped in new wire one length at a time. About a month after I did, I saw someone post the replacement harness site- if I had seen that before starting, would have bought the replacements without a second thought.

[professorman]

I need 4 for my two Boxsters. I am painfully doing them 1 wire at a time. I am soldering in new wire and using heat shrink tubing to cover sections that I can’t reach, as well as my solder connection points. I might make a video. I’ve done 1 headlight out of my 4 so far.