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Wiring to headlights badly corroded.

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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rguzz
Posts: 591
Joined: 7 October 2015
Year and Model: 1996 850 turbo
Location: VA
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Wiring to headlights badly corroded.

Post by rguzz »

Went to replace headlight bulb (96 850) and found wires on drivers side bare, with cracked and crumbled sheathing. Looked at the right side and found the same thing. If you haven't looked at these wires in a long time you might want to do so. I'm surprised I hadn't shorted out the light, burned something up, etc. Had no clue they were in such bad shape.

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default
Posts: 17
Joined: 3 November 2019
Year and Model: 1998 v70 awd
Location: South Carolina
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Post by default »

Mine are too, I’m looking for a way to swap them or repair them without killing me. I hate wiring 😡

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volvolugnut
Posts: 6223
Joined: 19 January 2014
Year and Model: 2001 V70
Location: Oklahoma USA
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Post by volvolugnut »

FCP has headlight connector part with wire tails P/N Flosser 4445 as a repair part. Use crimp connectors or solder the ends to your wire ends and cover with shrink wrap. Not too hard.
The insulation fails from heat and years.

volvolugnut
The Fleet:
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Year and Model: 1998 v70 awd
Location: South Carolina
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Post by default »

It’s funny, fcp has the whole harness but I didn’t see the parking light bulb on mine ( well, on the 2003 c70 lights I took apart)

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