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Old 06-03-2009, 08:37 AM   #1
Ryan314
Scooby Guru
 
Member#: 82989
Join Date: Mar 2005
Chapter/Region: NESIC
Location: Maine
Vehicle:
2002 WRX
Hybrid VF22

Default Replacing 9007 female connector

So my driver's side female headlamp connector is busted on my 02 WRX. I really don't know much when it comes to electrical. Does anyone have any write ups or tutorials on replacing one of these?

Thanks.
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Last edited by Ryan314; 06-03-2009 at 08:42 AM.
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Old 06-08-2009, 01:19 AM   #2
Captain Ned
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Location: Vermont, USA
Vehicle:
2010 Legacy2.5GT Ltd
Graphite Gray Metallic

Default

Just go to any auto parts store and buy a replacement socket, three 14-16 gauge crimp connectors, a crimper tool, and some heat-shrink tubing big enough to go over the crimp connectors.

Cut the dead socket off as close to the socket as possible. There's not much slack in a bugeye's headlight harness (having performed this very repair on my ex-Bugeye), so keep every inch of wire you can. Strip the ends of the newly-cut wires. Slide a crimp connector over each and crimp only the end the wire was inserted into. Once all three chassis wires have crimp connectors on them, slide the heat-shrink tubing over the wires of the replacement socket. Crimp the new socket on, making sure that the right wires go to the right wires (if the replacement socket wire colors don't match the chassis wires, label each replacement socket wire with the color of the wire it should connect to with a bit of masking tape and a pen). Once the new connector is fully crimped, slide the heat-shrink tubing over the connector and CAREFULLY shrink it with an external heat source. The proper method is a heat gun, but those are pricey if you don't have a friend with one. A grill lighter, held at a respectful distance from the tubing, will work well as long as you proceed very slowly and remember that you're working in a flammable-heavy zone.

Once all the heat-shrink is done remove the overwatt 9007 bulbs (the cause of my original socket failure), replace them with Sylvania XtraVision bulbs, and hook up everything.

For bonus points, strip the plastic cover from the crimp connectors before starting. Once the connections are made solder the wires to the metal bits of the crimp connectors with electrical solder (plumbing solder will cause the connection to corrode out in a few months), then make with the heat-shrink.
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