Headlight disconnection

Cluskera · Cluskera's Garage

Hi folks, I'm removing fenders and can get to wires behind headlight shroud/glass but I'm concerned I break a wire trying to pull through back of bucket.

Any tips or pictures of exactly what to remove / disconnect? I read in one post of applying a screwdriver to a sheath but not exactly sure what it meant.

Any tips greatly appreciated from experts here.

Thanks
Andrew

porwolf · 11-19-2013, 02:19 PM

I would push the wires back together with the rubber sleeves, from the inside of the head light buckets. Those rubber sleeves my have become hard though over time. Carefully applied heat might soften them up. If you heat up the rubber sleeves I would shield the exposed wires themselves with several layers masking tape. Also applying some oil around the holes in the headlight buckets that the rubber sleeves go through might help. Of course, you also have to remove the plastic housings that hold the quick-connects.

Bob Kontak · Bob Kontak's Garage

Quote:

Originally Posted by Cluskera

I read in one post of applying a screwdriver to a sheath but not exactly sure what it meant.

Cluskera · Cluskera's Garage

You are very good thank you for the help

Cooper911SC · 11-22-2013, 05:49 PM

You will also need a very small flat blade screw driver to remove the female electrical connections from the headlight connector and TS/running light connectors.

The plastic connectors won't fit through the holes in the light bucket with the harness.

The electrical leads are held into the connector by a small tab of metal at the center of the connector which is bent outwards.

You need to study the connector from the back (side the wires enter from) and insert the screwdriver in order to flatten the tab enough to remove.

Of course label the wire location first.

Cooper.

Bphawk1 · 11-23-2013, 07:20 AM

Does anyone know where to get the plastic connectors that the wires plug into in the picture. I did not see it in our hosts site.? Thank you.

Cooper911SC · 11-23-2013, 07:35 AM

Pelican should have them, however they are also commonly available at your local autoparts store.

Many people upgrade to a ceramic type as it will handle more heat if you are running high watt bulbs.

Cooper

Bphawk1 · 11-23-2013, 07:54 AM

I did find the plug where the headlight plugs into. I would need the other two plugs in which the turn signal wires plug together. One is a larger square plug and the other is the round plug in the diagram. I have had no luck finding those connectors. Any idea? Thank you.

Cooper911SC · 11-23-2013, 11:31 AM

Bphawk, those connector insulators are sourced from VW.
They just protect the M/F spade connectors.
You should be able to release the electrical connectors with small screwdriver and reuse.

If you are missing some or they are ruined, send me an email directly at cooper.boggs@gmail.com

I have some decent used ones. Give me your address and I'll mail them to you.

Cooper

Robert Adams · Robert Adams's Garage

When removing mine I hit the rubber with a liberal dose of vinylex and cleaned up the rubber a bit; no heat required. I took a #6 nail and hammered the 1st inch or so flat on a vise to fit down the connector to disconnect the wires. The nail end tends to round out and makes getting into that tight space pretty easy. Held the nail with pliers and it was aided by the use of a dental probe in removing the wires. The plastic connectors were pliable to work getting the tools in and the wiring out. Once the connectors were removed the rubber with the wires popped right out after being liberally dosed again in with vinylex and the small flat head screwdriver as in the above diagram.