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Wiring to headlights badly corroded.

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

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

rguzz
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Wiring to headlights badly corroded.

Post by rguzz » Fri Nov 29, 2019 3:30 pm

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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Re: Wiring to headlights badly corroded.

Post by default » Fri Nov 29, 2019 6:03 pm

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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Re: Wiring to headlights badly corroded.

Post by volvolugnut » Fri Nov 29, 2019 6:24 pm

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.

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2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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Re: Wiring to headlights badly corroded.

Post by default » Fri Nov 29, 2019 6:33 pm

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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