While trying to remove the headlight wiring harness from the support tube, pulling from the battery box is not giving success. Compressed Air blown into the hole in the battery box does not result in air coming out in the headlight bucket. Any hints on removing the stuck harness? Is this rust or dirt/sand in the support tube? Any experience on the best way to proceed, or do you just replace the bucket support structure? We are replacing the headlight bucket anyway. New Mexico car, so not a lot of rust elsewhere. 63 T6B Coupe.
Thanks, Rudy
removing headlight harness from support tube
- Rudy Bernhard
- 356 Fan
- Posts: 129
- Joined: Fri Apr 03, 2009 4:01 pm
- Location: Atlanta area
removing headlight harness from support tube
1960 Super Cabriolet, 1963 S90 Coupe
Registry #311
Owned Porsche 356s continuously since 1978
(wow, made 45 years of ownership on the 60 Cab!)
Registry #311
Owned Porsche 356s continuously since 1978
(wow, made 45 years of ownership on the 60 Cab!)
- Phil Planck
- 356 Fan
- Posts: 2035
- Joined: Wed Mar 26, 2008 7:21 pm
- Location: NE Michigan, lower penn.
Re: removing headlight harness from support tube
Remove bullet connectors. Cut away as much sheathing as you can. Pull one wire at a time.
Phil Planck
- Mike Wilson
- Classifieds Monitor
- Posts: 11637
- Joined: Tue Apr 15, 2008 4:37 pm
- Location: SW Los Angeles
Re: removing headlight harness from support tube
I had the same problem with one side of my car. I tried pulling one wire at a time; no go. Then tried reaming out as far as I could reach; still no go. Finally used a long drill bit to clean out as much as I could figuring it might be loaded ip with rust and/or crud. This after liberal application of Kroil. Then went back to pulling one wire at a time. I finally managed to start pulling wires but then found out the problem. There had at one time been a short in the wiring melting the plastic sheathing to the inside of the support tube.
Since the car is in restoration and the support tube has rust holes any way, the entire support tube/brace is being replaced.
Mike Wilson
Lomita, CA
'63 B coupe
Since the car is in restoration and the support tube has rust holes any way, the entire support tube/brace is being replaced.
Mike Wilson
Lomita, CA
'63 B coupe
Mike Wilson
Lomita, CA
'63 B coupe
Lomita, CA
'63 B coupe
- Martin Benade
- 356 Fan
- Posts: 12392
- Joined: Wed Nov 23, 2011 10:52 am
- Location: Cleveland, Ohio
Re: removing headlight harness from support tube
If the problem is not as severe as Mike's, possibly heating up the outside of the tube with a heat gun could help. That worked well for me, allowing the complete bundle to come out together.
Cleveland Ohio
62 Cabriolet
56 VW
02 IS 300
04 Sienna
62 Cabriolet
56 VW
02 IS 300
04 Sienna
- Mike Wilson
- Classifieds Monitor
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- Joined: Tue Apr 15, 2008 4:37 pm
- Location: SW Los Angeles
Re: removing headlight harness from support tube
Great suggestion, Martin. Heating it won't destroy the support tube either.
Mike Wilson
Lomita, CA
'63 B coupe
Mike Wilson
Lomita, CA
'63 B coupe
Mike Wilson
Lomita, CA
'63 B coupe
Lomita, CA
'63 B coupe
- Rudy Bernhard
- 356 Fan
- Posts: 129
- Joined: Fri Apr 03, 2009 4:01 pm
- Location: Atlanta area
Re: removing headlight harness from support tube
Martin, when it did come out, was there any crud, or was it just the sheathing and insulation had hardened up?
Rudy
Rudy
1960 Super Cabriolet, 1963 S90 Coupe
Registry #311
Owned Porsche 356s continuously since 1978
(wow, made 45 years of ownership on the 60 Cab!)
Registry #311
Owned Porsche 356s continuously since 1978
(wow, made 45 years of ownership on the 60 Cab!)
- Martin Benade
- 356 Fan
- Posts: 12392
- Joined: Wed Nov 23, 2011 10:52 am
- Location: Cleveland, Ohio
Re: removing headlight harness from support tube
I think there was some dirt, etc but maybe they were not stuck as badly as yours are.
Cleveland Ohio
62 Cabriolet
56 VW
02 IS 300
04 Sienna
62 Cabriolet
56 VW
02 IS 300
04 Sienna
- Rudy Bernhard
- 356 Fan
- Posts: 129
- Joined: Fri Apr 03, 2009 4:01 pm
- Location: Atlanta area
Re: removing headlight harness from support tube
moderate heating of the tube in the fender well was the key. But the outer wire sheath was stuck on some dirt in the tube, and the sheath split in the battery box. With the help of lubricant, the individual wires came out first. The empty sheath was removed second, after it let go of the dirt/crud in the tube.
No movement without the heat though. The wire insulation stiffens with age, and flexes after heating.
No movement without the heat though. The wire insulation stiffens with age, and flexes after heating.
1960 Super Cabriolet, 1963 S90 Coupe
Registry #311
Owned Porsche 356s continuously since 1978
(wow, made 45 years of ownership on the 60 Cab!)
Registry #311
Owned Porsche 356s continuously since 1978
(wow, made 45 years of ownership on the 60 Cab!)
- Mike Wilson
- Classifieds Monitor
- Posts: 11637
- Joined: Tue Apr 15, 2008 4:37 pm
- Location: SW Los Angeles
Re: removing headlight harness from support tube
Success! Glad to hear it!
Mike Wilson
Lomita, CA
'63 B coupe
Mike Wilson
Lomita, CA
'63 B coupe
Mike Wilson
Lomita, CA
'63 B coupe
Lomita, CA
'63 B coupe