12-11-2022, 11:30 AM
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#1
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Registered User
Join Date: Jan 2017
Location: Sarasota Florida
Posts: 42
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Headlight electrical wires bare, insulation falling off
Hi. I went to change hid headlight bulbs in my ‘04 today & I see all the wiring insulation is brittle & crumbling off. Has anyone experienced this, what was your fix? I thought I may try Gardner bender liquid electrical tape (LTB-400) & wanted to know if anyone here with experience in these things has any advice or cautions for me first.
(I’m on mobile platform & can’t upload pics. I’ll try to add some later when I’m at a computer)
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12-11-2022, 01:00 PM
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#2
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Registered User
Join Date: Feb 2005
Location: It's a kind of magic.....
Posts: 6,553
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You and about another million or so owners. Time to rewire them.
__________________
“Anything really new is invented only in one’s youth. Later, one becomes more experienced, more famous – and more stupid.” - Albert Einstein
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12-11-2022, 02:36 PM
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#3
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Registered User
Join Date: Sep 2022
Location: Seattle area
Posts: 62
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I pulled the entire harness out on my headlights and replaced it wire by wire. I don't have the pin removal tools, so I cut each one and crimped a new section on, then used heat shrink tubing to cover the connector. If you go that route, my main regret is I used the color of wiring I had without any thought on if it would be visible once the lights were put back on the car.
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12-11-2022, 05:59 PM
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#4
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Registered User
Join Date: Feb 2006
Location: Virginia
Posts: 1,734
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http://986forum.com/forums/boxster-general-discussions/54697-advice-used-litronics.html
This thread has information about opening the headlight and replacing the wiring. As JFP says, it is a common issue. Allegedly, the German auto manufacturers were using a biodegradable wire insulation during the time period in which our cars were built. In some conditions, it degrades faster than they expected.
__________________
2000 Arctic Silver/Black, Hard Top, On Board Computer
PNP Rear Speakers, HAES 6-Channel Amp, Avic Z140BH,
Painted Bumperettes, 2004 (OEM) Top, Homelink integrated in dash with Targa switch, 997 Shifter, Carrera Gauge Cluster with silver gauge faces, heated 997 adaptive sports seats, Litronics, silver console
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12-12-2022, 06:25 AM
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#5
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Registered User
Join Date: Jan 2017
Location: Sarasota Florida
Posts: 42
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Thanks guys. Guess I’ve got yet another project on deck. Been going that way lately, last month I moved a couple shrubs around the house & that turned into a renovation of my irrigation system.
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12-16-2022, 06:40 PM
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#6
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Registered User
Join Date: Sep 2008
Location: Florida
Posts: 2,498
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Down and dirty fix is electrical tape or liquid electrical tape on exposed wires. Not pretty and certainly not the final fix but it'll get you back on the road. Mine was still going strong a few years after the repair when the car was sold.
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01-06-2023, 11:41 AM
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#7
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Registered User
Join Date: May 2014
Location: Atlanta, GA
Posts: 95
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I'd go with rewire. german wires suck, they just do.
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01-06-2023, 01:16 PM
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#8
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Registered User
Join Date: Jan 2014
Location: Albuquerque, NM, USA
Posts: 743
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Quote:
Originally Posted by BrakeExpert
I'd go with rewire. german wires suck, they just do.
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No, in Germany auto parts are required to be biodegradable beginning in the 1990s.
These are performing as designed.
Same reason your radiator grilles ( non S) have biodegraded from black to gray
__________________
Kent Christensen
Albuquerque
2001 Boxster
2007 GL320 CDI, 2010 CL550
2 BMW motorcycles
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