Cracked/exposed wires in Headlight housing

I removed my headlamp housings to replaced the plastic lens with glass, and decided to replace the bulbs while everything was accessible.

I found a few cracked and exposed wires inside the housing.

Do you think good electrical tape be enough to fix, or does it gets too hot in the housing? Suggestions Slice some heat shrink ?

(2005 Golf MK4 GLS TDI)

From the photo, the insulation does not look overheated. and the wire conductors do not look damaged.

I would put some good quality tape on em, and be careful not to pinch putting it all back together.

You cannot slice heat shrink, kind of defeats the purpose. would have to pull the pin from a connector on one end or the other, or cut and splice.

I think the tape will be fine.

If you can unclip the wires from their harnesses, then I would go with the heat shrink. Had to do this to my EGR wiring due to rodent damage.

Unfortunately, I don't have the proper terminal release tools to get the connectors out of their housings, so it'll probably be tape, then.

Wires are not over-heated, btw, I've never used anything but stock DOT bulbs; it's just the soooooper high-quality wires VW used .... Vehicle only has 77K miles on it.

Sheesh, I've got 40-year-old Toyota Land Cruisers with better condition engine-compartment wire than this thing. Iloveit, Ihateit.

Thanks!

That looks like it was cut/stretched. Might have been pinched in the housing somehow.

ScottySK said:

That looks like it was cut/stretched. Might have been pinched in the housing somehow.

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No, it just cracked and broke when I removed the cover to access the bulbs. First time that cover has ever been removed, to access the high beam bulb. I know 'cuz I do all the work on my cars.

... Unless it was pinched at the factory, but I don't think so.

This is just very poor quality insulation on the wire.

Wish I had saved the wiring from my OEM HL's. I would have liked to have given them to somebody in need.

JB05 said:

Wish I had saved the wiring from my OEM HL's. I would have liked to have given them to somebody in need.

Click to expand...

Me, too.

Anyway, I just used some tape and I'm remounting the housings today. It was only on one side. The other side, wires were fine...

Thanks anyway!

One of these kits should help:

Both Sides:
http://www.fixmyvw.com/2-brand-new-...ng-harness-1999-5-2005-genuine-oe-components/

Single side:
http://www.fixmyvw.com/brand-new-co...ng-harness-1999-5-2005-genuine-oe-components/

I used this kit as my insulation on my wires were cracked. I saw it on one side but both sides were in bad shape. This is a great kit ! Heavy duty wire. Nice.

Thanks for the links - I saw these earlier, but after I had already repaired and reinstalled the housings... But I suspect I'll prolly have to replace them anyway, somewhere down the line, as the insulation on those wires is like brittle wax.

Go to the auto parts store and buy some liquid electrical tape, it is perfect for this application. This is what I am talking about..Mark