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Old 01-24-2019, 02:16 PM   #1
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Headlamp wiring harness

I finally removed one of my spare headlamp wiring harnesses to rewire them; lots of missing insulation.
What I am stuck with now is how to remove the wires from the connectors without damaging the connectors. The wire is missing insulation all the way to the connector pins, so splicing doesn't appear to be an option.

I would appreciate any assistance with this.




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Old 01-24-2019, 02:44 PM   #2
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There are tools for removing them, but who has the time for that?

I just use a small flat head screwdriver (jeweler) inserted into the slots on either side of each pin. Insert the screwdriver into one slot at a time and pry inward (toward the pin) to flatten the barbs.
This applies to the main connector.

For the other smaller bulb connectors/sockets, I just cut the wires close to the connector and solder on new wires, covering the joint and any exposed wiring left on the connector with heat shrink tubing.

Last edited by particlewave; 01-24-2019 at 02:54 PM.
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Old 01-24-2019, 02:50 PM   #3
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You can kind of see the side barbs in this picture:

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Old 01-25-2019, 04:23 AM   #4
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Quote:
Originally Posted by particlewave View Post
There are tools for removing them, but who has the time for that?

I just use a small flat head screwdriver (jeweler) inserted into the slots on either side of each pin. Insert the screwdriver into one slot at a time and pry inward (toward the pin) to flatten the barbs.
This applies to the main connector.

For the other smaller bulb connectors/sockets, I just cut the wires close to the connector and solder on new wires, covering the joint and any exposed wiring left on the connector with heat shrink tubing.
Thanks,

I'll give it a try this weekend.
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Old 01-26-2019, 08:51 AM   #5
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Can I ask what gauge wire is used for the parking lights? I need to reside those sockets and disable my failed angel eyes after I get my car back from its engine rebuild. Thanks!
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Old 02-02-2019, 10:24 AM   #6
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Can I ask what gauge wire is used for the parking lights? I need to reside those sockets and disable my failed angel eyes after I get my car back from its engine rebuild. Thanks!
I watched a headlamp rebuild youtube video and the guy used 18 gauge wire throughout
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Old 02-02-2019, 01:48 PM   #7
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I watched a headlamp rebuild youtube video and the guy used 18 gauge wire throughout
Thanks, I appreciate that!

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