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YOUR RESEARCH996.1 internal headlight harness failure
Leading reported evidence
Install i found the wires are toast
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Leading evidence: 'Install i found the wires are toast' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Install i found the wires are toast' (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.
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These lights were new when installed on my vehicle in 2005 (after a mishap.) You can see the near total deterioration of the wire cladding.
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One by one, I extracted a connector from a plug and installed shrink wrap over it and the wire.
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I replaced a couple sections of wire, used liquid electrical tape on a few other small spots.
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I'm installing the Retrofit Labs kit on my car and ran into this issue.
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Suggestion
Not only is the shielding breaking off from the wiring and causing a short, but the plastic receptacles are also becoming brittle and break when attempting to change a bulb.
Replace harness in the halogen headlights (pictured here) you need
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Suggestion · Original poster
Also, in order to replace the harness in the halogen headlights (pictured here) you need to completely disassemble the lights by removing the Permasealed lens.
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Suggestion · Original poster
Since it is readily accessible, it is easier to either replace those wires or use either electrical tape or liquid electrical tape or shrink tubing to insulate those wires.
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It is a known issue that the insulation on the 996.1 internal harness fails, but I couldn't find a specific post on the subject in this forum.
Since I just had to deal with this while retrofitting a set of 996.1 headlights, I thought I'd start a thread for future generations and general info.
Here are some pictures of what the harness looks like after 20+ years:
Obviously a bad situation when bare copper is present and a recipe for disaster.
The problem is that Porsche doesn't sell these harnesses separately. Also, in order to replace the harness in the halogen headlights (pictured here) you need to completely disassemble the lights by removing the Permasealed lens.
I am working on coming up with a replacement harness, provided I can source the proper connectors. Alternatively, I can rewire the harnesses using the existing connectors, which is what I did with this one. Pictures of before and after:
Before:
After:
More info on this to follow!
Haven't looked into the 996.2 harness yet. I think it is a more complicated harness with more special connectors. Being able to source them will be key.
I could rewire existing harnesses like I did the one in the pictures, but that may not be very practical...
Soy based wiring insulation! Great F*kin� idea
whoever spearheaded that project should be flogged in the public square!!! How stupid can you possibly be???
(3 more for good measure) 🤬🤬🤬 (I guess it seemed like a great idea at the time�)
I'm installing the Retrofit Labs kit on my car and ran into this issue. I replaced a couple sections of wire, used liquid electrical tape on a few other small spots. I see the same thing on my '07 Z4 which means German manufacturers didn't learn their lesson over that 5 year period.
This wiring problem certainly happened with my 996.2 lights. These lights were new when installed on my vehicle in 2005 (after a mishap.) You can see the near total deterioration of the wire cladding. I did some searching on this topic when I discovered my problem. I think it is pretty common. To stabliize things, I used shrink wrap. One by one, I extracted a connector from a plug and installed shrink wrap over it and the wire. I think 3/16" fit over the connectors. I slid it over the wire and then heated it to seal it around the wiring. The rubber grommets complicated things. In the first photo, you can see where I sliced the grommet. I did that to remove it to get the shrink wrap over the connector. Then squeezed it back into place. I didn't bother with the ground wires (brown) I think this fix will last a while. btw, I'm also miffed that the black plastic trim that provides the seal to the fender and hood is deteriorating and I don't think there are replacements. Below, one photo shows one shrink wrap tube in place over a wire. The second photo, the general condition of the wiring in the light.
on to the 996.2.
"I'm also miffed that the black plastic trim that provides the seal to the fender and hood is deteriorating and I don't think there are replacements."
KeyWest, you are correct there is no replacement for the Outer seal on the Headlamps. But I did find a suitable replacement at low cost in a common high temp rubber tubing. Just search and you find my post, in replies to this very common issue.
Jack, Thanks for mentioning that. I did come across your post while researching this topic but as I had most of the pieces of trim I was able, with the use of adhesive, extend their life. GA
I have just purchased the Retrofit Labs kit to upgrade my halogens. The kit is spectacular but unfortunately, I found the same crappy wiring. Fortunately, I was able to remove the harness without removing the outer lens and I'm In the process of redoing the harness. I plan on posting pictures and instructions when I get this done.
question on this, on the second photo, that�s the turn signal, is that a separate small harness? My passenger signal doesn�t work, I bought new bulbs and no luck. I�m thinking that harness is dead. But idk if I�d have to switch the WHOLE thing�
Hi Eric,
The second picture shows the external "harness" for the blinker function. This is separata and NOT included in the replacement harness that I sell. Since it is readily accessible, it is easier to either replace those wires or use either electrical tape or liquid electrical tape or shrink tubing to insulate those wires. If you are not comfortable doing that, feel free to PM me about sending them in to me to replace the wires!
Thanks for posting Joe! It's good to know there are options out there for these lights. It seems a lot more of these first run Bosch headlights with the soy based wiring are having this issues. Not only is the shielding breaking off from the wiring and causing a short, but the plastic receptacles are also becoming brittle and break when attempting to change a bulb. It they weren't so blasted expensive to replace, but Porsche wants over $2000 each for these enclosures.
I use ALL NEW connectors and wiring on these harnesses, so you'll be good for at least another 20 years! I offer tem for the 996.1 halogen and litronic, sadly I am unable to offer them for the 996.2 (which I own myself) as it has too many specialty connectors that I am unable to source.
--Adrian
I am facing this dilemma after purchasing the Retrofitlabs halogen -> led kit. My wires are toast.
How did you remove the internal harness (within the headlight enclosures)?
Thank you!
With much difficulty, lol.
The 996.2 harness plug has two clips on either side that need to be depressed from the inside in order for it to dislodge from the housing.
Personally, I think it can't be done with the lens installed.
Even with the lens removed, I had to design my own tools to get it to come out. Still, sometimes it takes me 2 minutes, sometimes 20
Porsche gonna Porsche.
When you say lens do you mean the bulb lens or the actual clear part of the housing? I can certainly remove the internal bulb lens, take apart the housing is another matter.
If the latter, what's the safest way to disassemble and reassemble the housing?
I meant the lens separated from the housing. I put the lights in a carboard box and put a heat gun through a small opening for 20 minutes at 500F. Then use screwdriver to make a start and use plastic prying tools to run along the seam to separate the two. Takes some patience and sometimes reheating. I use butyl rubber to reassemble. I can sell you the plastic tools and the butyl rubber if you want.
I offer this service but usually as a combination of harness refurbishment with installation of an RFL kit as I am their US distributor.
[Image-only post; no author-written text. Original image references:]
https://cimg1.ibsrv.net/gimg/rennlist.com-vbulletin/2000x1504/2024_03_01_16_22_29_672cdc9795f8f46794f3629c9c1d59f8293fcdd9.jpg
Oh! I believe I found your website
after
I had already ordered direct from them. I bought the halogen to LED retrofit with the H9 AvantiLED bulbs. When I installed I found the wires are toast. Right now every inch is wrapped in electrical tape and the Avanti's don't light (but I still have some form of highbeam, from the low beam LEDs?)
Yes, the bi-LED means that the projectors function as running lights AND high beams. I have the Avanti's in my car too and in combination with my Bi-Xenon RFL projectors the light output is nothing short of amazing!
The light set pictured above is one I did for a customer recently, as you can see it has the Avantis as well!
Hey! This is my first post, so feel free to flame away! I just picked up a 2004 Carrera Cabriolet with one headlight not working. I read the posts and decided to use some liquid electrical tape on the abysmal deteriorating wires. Turns out the liquid electrical tape was beyond it's 'sell by' date, so I had to come up with something else. I ran a miniature file over the electrical contacts -where the light assembly plugs into the body, and then applied a light coat of dielectric grease on the contacts. I reinstalled it, and Voila! It lights! I hate the fact that I still have those nasty wires, but I needed my car to pas inspection to get it registered, so I'll deal with the nasty wires another day. I hope this is useful to someone!
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