Driver headlight (Lowbeam) out due to loose wire at socket connector

[xcinla]

So, my newest discovery on my 2004 2.5 is that the driver headlight is out. I pulled the headlight out and found that one of the two black wires feeding the connector (that the back of the H11 bulb plugs into) is loose / was able to pull it out (where the Red box is on the pic below). I pushed it back in while the car was running and the bulb lighted up but the wire won't stay.

There's a replacement part (below) but how do you replace it? The wires go back into the headlight assembly somewhere. I assume the other end of that wire is plugged/connected into some slot but it doesn't appear to be accessible. Has anyone done this?


headlight socket.jpg


https://www.fcpeuro.com/products/vol...volvo-31299732

[88domer]

Just cut off the old connector and splice the new one onto the wires:

https://sparkys-answers.com/2013/01/...-not-work.html

It’s been a few years now so I can’t recall exactly how I did it, but my connector melted on my ‘04 and I replaced the entire harness inside the headlamp assembly with another that I pulled from the junkyard. It wasn’t too hard, just a tight fit and a bit of fishing to get the harness to curl correctly.

BD

[xcinla]

THanks. I'll splice in the new connector and call it a day.

[cn90]

Check to be sure, but if you have H7 bulb, but the H7 headlight connector, the ceramic type is supposed to be better.
Local auto parts store, ebay or FCPEuro should have it.
The debate is plastic vs ceramic...

Polarity is NOT important here, but you may want to keep the same wiring, just watch which wire goes where.

Use a butt connector and crimp it.

This is a good video, but where the guy connected (he twisted the 2 wires together), don't follow his advice, instead, use butt connectors...
In fact, if you watch carefully, there were already 2 butt connectors (YELLOW connectors in his video).
So the connector was already replaced at least once before in his car...

[xcinla]

Thanks. I have the H11 bulbs as my low beam on my 04 2.5T and not the H7. As far as I know, that's how it came (oem). I ordered the connector from FCP and it should be here around wednesday. I think it's plastic but I don't think it' matters since the issue was not the connector melting but rather one of the wires coming lose from the back of the connector. I can't get it to go back in and stay so I'll just swap in a new one. The h11 bulbs are 55 watts so i'm sure there's heat generated. I thought about LED bulbs but it's a 15 year old car so... cost / benefit that one.

Check to be sure, but if you have H7 bulb, but the H7 headlight connector, the ceramic type is supposed to be better.
Local auto parts store, ebay or FCPEuro should have it.
The debate is plastic vs ceramic...

Polarity is NOT important here, but you may want to keep the same wiring, just watch which wire goes where.

Use a butt connector and crimp it.

This is a good video, but where the guy connected (he twisted the 2 wires together), don't follow his advice, instead, use butt connectors...
In fact, if you watch carefully, there were already 2 butt connectors (YELLOW connectors in his video).
So the connector was already replaced at least once before in his car...

[xcinla]

Just fixed it.

Cost me about $70 or $80 in parts (connector from Fcpeuro, wire stripper, butt connector pack in various sizes) but it’s cheaper than a new headlight and I avoided the labor cost of taking it to somebody.


Miller time