Headlight Headcase

Tony Hoffman auditony at gmail.com
Mon Feb 13 09:11:46 PST 2012

I've seen a lot of these cars now with wiring problems inside of the
headlight assembly. Mostly, been seeing the insulation falls off the wires,
and causes blown fuses. On the B5's and C5's you can heat the edge fo the
light where the clear plastic goes into the black portion. I use a heat
gun, but in the oven works as well. pull the clear cover and you can get to
everything. I've replaced all the wires on about 20 of these so far. Also
happens to the B6's, but the clear into the black is done with urethane, so
they will not come apart very easily. As in, not any way that I will do to
a customer car. So, you just have to take your time and replace the wires
you can get to. BTW, all the cars I've dealt with that have these wiring
issues are non-HID cars.


On Mon, Feb 13, 2012 at 9:42 AM, mkb <mkb125 at yahoo.com> wrote:

>  So, as soon as I got home, I popped the hood, removed the inner headlight
> cover, and began moving the wires to the low beam.  As soon as I moved the
> top wire a bit, the low beam came on.  I could have swore I did this last
> time.  Why was it working now?  I looked at the connection a bit closer and
> noticed that it had corroded and so the connection was no longer tight.
> Those words of collective list wisdom must have cast some wierd spell on
> that harness that day.  Sometimes it doesn't make any sense at all.  Or
> maybe I'm just
>  getting old.
> Anyway, I finally went to the local auto store, bought some wire, pulled
> the light, spliced in the new wire and connector and voila, the light is
> now working as good as new.  I no longer have to worry about getting home
> before it gets really dark, or leaving the avant and taking another car
> when it's dark out.  Like I said, sometimes it doesn't make any sense.  And
> I am getting old.

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