wire damage in headlights

[longrowe]

I have a 1998 RoW Coupe. Yesterday I pulled the left headlight to replace the parking bulb. When I pulled the socket out, the insulation completely crumbled off the wires. Completely. So I had three bare wires from the socket to the wire loom. Evidently, 130 degree desert heat for 15 years is not so good for wire insulation. Anyways, is there a way to replace just the internal wire loom without replacing the entire headlight assembly? I imagine both sides will be similar.

 

The next best thing would be to manually replace all of the wiring. I have found a place that sells 20AWG wire with automotive markings. I can cut and solder in new wires and rebuild the harness but looking to see if anyone knows of a more plug and play solution that won't make my wallet cry.

 

Thanks!

[Randy Remington]

May seem unorthodox, but consider "liquid tape". It can be found at most home improvement stores in the electrical section. I simply pulled off the crumbling insulation and painted over the exposed wire. Worked like a dream for my 99 996.

[KevinH90]

I ran into the same problem when I was refurbishing a set of litronic headlights.  You can read about it here: http://986forum.com/forums/general-discussions/54697-advice-used-litronics.html

 

I ended up opening up the headlight and replacing the wires.  I was reluctant to do it, but it is not that difficult.  There is a good discussion of how to do it in the thread including some pictures of replacement wiring.  Randy's suggestion sounds like it would be less work. 

 

It appears that the problem is due to a German law that required the use of biodegradable wire insulation.  There are references to Mercedes with the same problem.  It may be better just to replace all the wire so that the problem does not return.

 

Good luck.

[longrowe]

I think I will get some hookup wire and re-wire them. Thanks for all the replies.