997 wiring basics - how to save $2894 dollars and not get sticky fingers
#1
02-25-2011, 02:14 PM
Join Date: Jan 2007
Location: OR Room 5
Posts: 10,784
Rep Power: 1006 
997 wiring basics - how to save $2894 dollars and not get sticky fingers
I am not sure if anyone will find this useful immediately, but I'm fairly certain that at some point, some time in the future, it will come in handy for either a member, or a desperate VW, Audi, or Porsche owner that Googles the right phrase.
The electrical harnesses in the 997 are made by Tyco, who OEMs wiring harnesses for VW and Audi. Porsche shares the same connectors.
When I recently tried to swap tail lights, I found that the plastic retaining clip was very brittle when Wisconsin temps fall in winter. The clip broke, and while the harness will hold together, vibrations could possible separate the two.
The culprit:
Cost of replacing entire rear wiring to replace single wiring broken harness - $2900 + $400 labor.
Cost of replacing rear wiring harness with salvage yard harness, then soldering the wiring - $250-300.
Using epoxy or adhesive - probably will crack off the next time you pull at the wiring harness.
Solution:
TYCO OEM distributors for VW and Audi:
How to do the swap correctly...ie without destroying the wiring, retaining clips, harness.
1. Release the secondary retainer:
2. Once the secondary retainer has been pulled, use either a wire terminal extractor or (in my case since the tool is $75-100) two unfolded staple loads.
3. Insert the release pins into the appropriate slots then wiggle the wiring out of each hole:
4. Replace the wiring into the slots one by one:
5. Finally, one of the wiring plugs is a blank - push out the white rubber seal and insert into the new harness...and then you are done!
The electrical harnesses in the 997 are made by Tyco, who OEMs wiring harnesses for VW and Audi. Porsche shares the same connectors.
When I recently tried to swap tail lights, I found that the plastic retaining clip was very brittle when Wisconsin temps fall in winter. The clip broke, and while the harness will hold together, vibrations could possible separate the two.
The culprit:
Cost of replacing entire rear wiring to replace single wiring broken harness - $2900 + $400 labor.
Cost of replacing rear wiring harness with salvage yard harness, then soldering the wiring - $250-300.
Using epoxy or adhesive - probably will crack off the next time you pull at the wiring harness.
Solution:
TYCO OEM distributors for VW and Audi:
How to do the swap correctly...ie without destroying the wiring, retaining clips, harness.
1. Release the secondary retainer:
2. Once the secondary retainer has been pulled, use either a wire terminal extractor or (in my case since the tool is $75-100) two unfolded staple loads.
3. Insert the release pins into the appropriate slots then wiggle the wiring out of each hole:
4. Replace the wiring into the slots one by one:
5. Finally, one of the wiring plugs is a blank - push out the white rubber seal and insert into the new harness...and then you are done!
Last edited by bbywu; 08-31-2012 at 12:06 PM.
#2
02-25-2011, 02:16 PM
Join Date: Jan 2007
Location: OR Room 5
Posts: 10,784
Rep Power: 1006 Last edited by bbywu; 08-31-2012 at 12:04 PM.
#6
02-25-2011, 07:01 PM
I fixed cars for 20 years, And every car I worked on these clips always broke.
if it does come lose you can do the poor mans fix and take some silicone sealer..
it would hold it from coming lose, but still be easy to remove if needed.
if it does come lose you can do the poor mans fix and take some silicone sealer..
it would hold it from coming lose, but still be easy to remove if needed.
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#10
02-25-2011, 09:07 PM
Join Date: Jan 2007
Location: OR Room 5
Posts: 10,784
Rep Power: 1006 bob
#11
02-25-2011, 09:09 PM
Join Date: Jan 2007
Location: OR Room 5
Posts: 10,784
Rep Power: 1006
Thanks guys!
Dave, you read my mind. Tech1 wheels on the way.
Done!
Thanks for all the compliments. I'm not sure if anyone here will find this useful today. But some day, somewhere, someone else who is equally compulsive...hopefully...will find this of use.
bob
Done!
Thanks for all the compliments. I'm not sure if anyone here will find this useful today. But some day, somewhere, someone else who is equally compulsive...hopefully...will find this of use.
bob
#14
02-25-2011, 09:53 PM
Although he makes the repair easier then it is..getting those wires out can be a PIA...so be-careful if you attempt it.
