Broken Headlamp Connector Housing

[marksstrauss]

Hi,

After replacing a halogen headlamp on my 2000 Boxster-S, I ended up breaking the plastic connector housing. I can guarantee that I won't do this again, as I finally figured out that I needed to align the guides on the pad to the tracks in the headlamp opening. No, I didn't think jamming the pod in there felt right, but did anyway. Oh well, live and learn.

I ordered a new connector housing and clip, thanks to RennTech pointers to (1) the 986 USA parts catalog and (2) Pelican Parts. With these parts in hand, I figured it shouldn't be too difficult to replace the connector housing and clip.

What I can't figure out is how to remove the wires and connectors from the broken housing and put them into the new housing. I don't think the wires and end connections are easily pulled out from the broken connector housing. I then figured I should just

1) mark/clip each wire (7 in all) from the wiring harness,

2) solder on short extensions and clips,

3) push the clips into the new housing,

4) replace the new connector housing (OEM-99965015040) and headlamp fastener (OEM-99663124500),

5) put the headlamp assembly back in (using the guides, of course)

The problem is that Pelican Parts doesn't have the clips connected to the ends of the wire, the clips that go inside the connector housing and end up connecting to the metal tabs in the headlamp pod. I was told that I needed to order a new wiring harness (~ $400.00). Is there an easy way to get the clips out of the broken housing and put them into the new housing? I can't see spending $400 for 7 metal clips that should cost less that $1.

Thanks in advance!

Regards,

Mark

[whall]

Mark,

Have your Porsche technician (not parts guy) check his “Porsche Electrical Connector Repair Kit” for the replacement parts or at least a part number for the parts you need. The entire repair kit is known as CARTOOL – Nr 96 0 000 or PNA 721 043 600. It is full of connectors the parts guy would like to sell you the entire wiring harness for.

Bill

[marksstrauss]

Bill,

Will do! Thanks for the info.

Mark

[Jinster]

I have often found that when it comes to connectors, a lot of this stuff is quite generic. I have hooked up the intermittent wiper knob and the auto dimming mirror harnesses with just $0.6 worth of generic connectors from Jaycar (Oz electronic hobby store) with perfect fits (not just the metal blades, but the actual plastic housing too is a perfect fit - this would unlikely to be the case for the headlamp connector, of course).

Your local electronic hobby store should be able to get you something very close - you can always take a pair of pliers and bend an "almost fit" into an "exact fit".