8 captured repliesDiscussion pagination complete · Source accounts, not a confirmed diagnosis
THIS DISCUSSION / SOURCE-DERIVED OVERVIEW
Discussion summary
YOUR RESEARCHHeadlight Cracked Insulation
Leading reported evidence
Run about 2 bucks apiece
Performed · outcome unconfirmed
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that performed work without a confirmed outcome
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Performed · outcome unconfirmed · Original poster
Where I needed to splice, I use raychem aircraft environmental splices; they run about 2 bucks apiece, but thew work well in all environments.
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Like many, I have a set with deteriorated wiring that I would like to see repaired rather than replaced with a new set that most likely would have the same problem again in time.
Leading evidence: 'Run about 2 bucks apiece' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Repair rather than' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
Source reports, not a diagnosis or a success probability. Counts refer to discussions and can overlap.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that performed work without a confirmed outcome
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that performed work without a confirmed outcome
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Performed · outcome unconfirmed · Original poster
Where I needed to splice, I use raychem aircraft environmental splices; they run about 2 bucks apiece, but thew work well in all environments.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Like many, I have a set with deteriorated wiring that I would like to see repaired rather than replaced with a new set that most likely would have the same problem again in time.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Like many, I have a set with deteriorated wiring that I would like to see repaired rather than replaced with a new set that most likely would have the same problem again in time.
These are separate views of the same evidence. Frequency alone does not establish a fix, and these counts must not be added together.
Repair rather than
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Like many, I have a set with deteriorated wiring that I would like to see repaired rather than replaced with a new set that most likely would have the same problem again in time.
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Like many, I have a set with deteriorated wiring that I would like to see repaired rather than replaced with a new set that most likely would have the same problem again in time.
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Like many, I have a set with deteriorated wiring that I would like to see repaired rather than replaced with a new set that most likely would have the same problem again in time.
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
8 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.
1 acknowledgements have no verified action link; they do not establish a repair result.
Outcome without a verified action link
I stumbled on an old extraction tool at work that worked like a champ.
Been dealing with dim headlights so upgraded the bulbs a few weeks back and discovered the disintegrating headlight wiring. I've seen this before on a W211 benz, but for 500 bucks I just went with new Hellas. $2500 for new 996 Halogen Headlights; OUCH!
At first I was gonna swap out all connectors, terminals, and just run new wires. Unable to find the Hella Main Plug, but did source the pins. But then I'd also have to source all of the unique connectors and terminals inside the assembly.
Decided to pop the lens and shrink tube the wires.
The power wires wer easy as once the pin was extracted, heat shrink over the pin and wire, then restab the pin and call it good. Not so easy on the return wires as they were doubled up. So those once, I found a convenient spot in the middle to cut the wire and the heat shrink and splice. All came out quite acceptable. Where I needed to splice, I use raychem aircraft environmental splices; they run about 2 bucks apiece, but thew work well in all environments.
For the dim headlights, discovered the projectors were mildly hazed obstructing the light. So once the lens were removed, they cleaned up quite nicely. First one took quite a while as I tried to find a way to rewire without popping the lens. Once I committed to the lens and mentally prepared to buy now assemblies, the rest was easy. 5 Minutes in the oven at 200 degrees. A little careful prying to get the party started, and off it came.
All tested on the car with lens still off. Tomorrow I will get a bead of Butyl Rubber set the lens's, rebake them and press fit.
Some additional Info. Some folks are saying that the wiring is deteriorating due to heat in the housing. I disagree as the wiring is cracking from end to end and is not localized to any hot areas of the housing, Also note that the Brown and Black wires that go to the Fog Lamp are 100% intact. In fact, they appear to be brand new. This is a completely different type of wire and is not affected by the deterioration at all. Also note that this is not a Porsche Defect, but a Hella Defect. Other forums are showing this has occurred on BMW's and I've seen it myself on an E-Class Benz.
Hella is quite proud of what they do, but nowhere do they admit that they messed up on this. They should be selling Lens's and internal wiring harnesses. I was able to find pins for the Main connector as well as pigtailed connectors for the halogen H7 bulbs. I opted not to change the pins or terminals, as I feel cutting and splicing are going to be just fine long term.
In a perfect world, I would have sourced all the terminals and connectors and restored to new with high temp 18 gage wiring.
I did find it challenging to remove the terminals from the main connector and tried the small tab type automotive contact tools with no luck. I stumbled on an old extraction tool at work that worked like a champ. Picture included. It is an Elco 06187704. I'm sure there are other tools, but this one works perfect. Insert the dual release tabs until a click is heard, then push the center plunger; terminal slides right out.
ELCO 06 1877 04
Main Connector Pin Extractor Tool
masc243 -- where did you find the pins? Internals on my halogens are crumbly. I don't think there's any tricky connections in there except for the turn signal, so a full replacement (with maybe an accidental LED upgrade
) would certainly make for a cleaner project.
For anyone that has this same problem of biodegradable wiring insulation, I just want to mention that I can rebuild those harnesses as part of the Retrofitlab upgrade to bi-LED or bi-Xenon.
That way your headlights will be better than new: better light output, new wiring and for a limited time I'm including a free lens restoration!
www.retrofitlab.us
Any chance you are still willing to rebuild a set of 2000 996.1 C4 headlights with the Retrofitlab upgrade to bi-LED? Like many, I have a set with deteriorated wiring that I would like to see repaired rather than replaced with a new set that most likely would have the same problem again in time.
This is a source reference. Confirm exact model applicability in the original material.
