Advanced Search

Gers wrote: wrote:

Driver side dipped headlight would glow a dull orange then go off ... replaced the bulbs and checked the fuses - No change! ... Then found that the pin connector plug for the headlamp showed signs of burning on one pin hole .... Cleaned it and made the pin hole a tighter fit .... All fine now

I had a problem with overheated wiring to the dipped headlights in mine a while ago. Pictures, including the repair, are here.

The nearside dipped headlight on my 2004 TF packed up. An inspection revealed that it wasn't the bulb but the bulb connector and wiring inside the lamp. I sourced a pair of H7 connectors from eBay and set about repairing it.

I removed the cover from the back of the lamp


You can see the scorched yellow wire. The insulation on the blue wire has disintegrated


The connector has melted too


I cut the wires about 3cm from the connector as the insulation seemed OK here


Here is the new connector, tinned and ready to go, complete with heat-shrink tubing


All soldered and insulated.

Ideally, I would have liked to have replaced the whole length of wire (the leads on the new connectors were long enough) but I couldn't figure out how to. The offside dipped headlight not quite so bad but will be repaired the same way. The main beam lights are perfect, presumably because they don't get used as much, as talkingcars suggested.

I've tried (3 times) to upload a scan of the relevant page from my TF (2004) owners manual without success. I don't why, I've never had trouble with images before. Only about 5% of the picture appears.

The bottom line is that if you take off the rubber cover behind the dipped headlight bulb there is supposed to be a lever. you simply (!) move this to the alternate position. Repeat for the other side.

I'll try to upload the scan again later but if you PM me with your email, and I'll email it to you.

Bruce.

I had to replace the nearside dipped headlight bulb recently and found that the connector needs to be replaced. The plastic on the connector is falling to bits and the insulation on the wires is brittle, falling off and exposing the copper within. It looks like heat damage. The offside is the same. I haven't looked at the main beam connectors yet but suspect the same too. I've made a temporary fix but need to make a proper repair. The connectors are easily available.

My question is how easy is it to replace these connectors and wires? I presume I need to remove the front lamp units. There doesn't seem to be a how to for this. Is it straightforward? Any advice appreciated.

The parts I am talking about are these:

H7 2 Pin Headlight Replacement Repair Bulb Holder Connector Plug Wire Socket Buy It Now