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Headlight connector just...crumbled? (95 Subaru Legacy L)
Posted 18 October 2013 - 08:48 PM
So, I'm a bit concerned...Do I now have a completely broken headlight unit? Can this connector be replaced? Is it easily doable? And moreover, is it expensive?
Im guessing the whole thing was dry rotted? The inside of the connector is corroded, complete with green oxidation on the wire. I'm thinking the bulb itself is not dead, since at one point the high beams worked for a second when fiddling with it (had the car on after it shattered to check if the driver side light still worked, lucky, it still does.)
Posted 18 October 2013 - 09:35 PM
Every damn one does that. Go to an autoparts store and buy a replacement connector. I know napa has them.
I've had more than one of those connector melt on more than one car, they eventually changed it around 97.
Posted 18 October 2013 - 10:22 PM
I was replacing mine once a year. I just used to cut them all off of every sooby i found in scrap yards to have a stock of them. The cause is that over the years of heating and cooling the blade connector loosens up ( or the wire to it corrodes) and causes the connection to overheat, melting the socket.
Posted 18 October 2013 - 10:25 PM
Posted 18 October 2013 - 10:26 PM
Every parts place I've seen sells replacements. A pair is usually $12-15. Solder and heat shrink the wires together, or use the heat shrink type crimp connectors.
Posted 18 October 2013 - 10:48 PM
Posted 18 October 2013 - 11:15 PM
soldering is really easy.. if you don't own wire strippers it's easy just match the color wires up strip the wires and use heat shrink tubing.. tin the wires and solder the two together.. let the wire cool then slide the heat shrink tubing over the area you connected and heat it so the tubing shrinks down over it.
Posted 19 October 2013 - 07:02 AM
Slide an extra piece of heat shrink tubing over the wire before you put the connector on in case you damage the heat shrink on the connector. The cheap crimp tools don't always play nice.
Posted 19 October 2013 - 07:34 AM
get some heat shrink tubing, close to the size of the wires (it comes in many sizes)
there are 2 types - a plastic looking type (shiny) and a rubbery type - the rubbery type is the better product by far.
Cut a piece of the heat shrink tubing about 2 inches long
Strip the ends of the wires about 1 inch
Slide the piece of heat shrink over one of the wires & out of the way.
Twist the stripped wires together tightly, like this:
Slide the heatshrink down over the twisted bare wires so it covers about 1/2 in of insulation on both sides of the repair.
Apply a heat source to the heat shrink (a common cigarette lighter works fine, just keep it moving), starting in the middle and working out to the ends until it has shrunk down snugly around the repair - it should look like this when done:
I have made many, many wiring repairs using this method over the years, both on cars and on semi trucks, and have never had a problem with them corroding inside the repair. Even repairs that were very exposed to the elements - such as wiring for marker lights on a semi trailer - for extended periods held up just fine.
Posted 19 October 2013 - 07:53 AM
Don't solder it. Use heatshrink crimp connectors. I don't like soldering on car wiring anyway. Where the soldered wire transitions to not soldered wire there's a hard spot. Over time and vibration, it has a tendancy to break right there. Crimping with the sealing heatshrink connectors is the best way.
I do a lot of marine work, and it's the same deal there. If I can use a crimp, that's the best option.
Posted 19 October 2013 - 12:21 PM
You guys rock, heartless that guide helped out so much, thanks a bunch ! I'll do as you guys suggested an go the heat shrink route. I'll keep you all posted.
Posted 19 October 2013 - 05:11 PM
The replacement I got is white with all black cables, looks like this:
The guy at advance auto had no clue which was what, so I attempted to splice and crimp...no result. I'm at a loss.
Edited by HadrianV, 19 October 2013 - 05:12 PM.
Posted 19 October 2013 - 05:15 PM
Hopefully you didn't blindly cut off the old connector without seeing where the wires went... Whenever I do these, I cut one wire at a time.
Cut a wire off the old connector, and match it up to the same pin on the new connector. If you do it one at a time, you won't get lost.
Posted 19 October 2013 - 05:21 PM
am utterly lost, is there any way I can figure out what's what?
Edited by HadrianV, 19 October 2013 - 05:23 PM.
Posted 19 October 2013 - 05:42 PM
Progress, gentlemten. Progress.
Posted 19 October 2013 - 07:11 PM
There are much better weather proof plugs available.
They look just like the factory ones, except have big fat wires, and even have the rubber boot on them.
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