Using liquid electrical tape to fix flaky insulation on headlight wiring

[hattac]

2006 E66

I’ve cut open the headlight lens to replace them with a new pair. Inside the headlight body, I can see the wiring has lost most of its insulation. What’s still there is flaking off as I touch it.

Can I use liquid electrical tape/insulation to “make” a sleeve on these wires? If not, is there another solution?

I have already replaced the fiber optic lines for the angel eyes with new ones, so that’s not a problem. I’m talking about all the other wires in there that’s flaking its insulation.

[grannyknot]

Sure that will work, just know that the hardened liquid tape will be subject to the same heat levels as the old insulation.

[BlkGS]

I'd recommend flaking all the old insulation off first. The liquid tape isn't going to really help much if the substrate it's bonded too is weak and flaking. It will just come off with the flaking insulation.

[tracer bullet]

I'd consider shrink wrap if they can be easily backed out of the connectors and gotten to. Don't cut them for it though.

You might have to consider replacing them altogether. Not fun, but do-able.

[Chihuahua]

Originally Posted by tracer bullet

I'd consider shrink wrap if they can be easily backed out of the connectors and gotten to. Don't cut them for it though.

You might have to consider replacing them altogether. Not fun, but do-able.

They can't unfortunately, you'd have to remove the lens and basically gut the housing.

OP, I had this same problem on my E60. I ended up just replacing them, but there were a lot of guys on the 5series.net forum that did exactly what youre considering and they were all successful with it. They didn't bother with removing the old insulation, they'd remove the access covers and the bulbs and spray away. Seems to be a widespread problem for BMWs of that era. If you do replace them, just remember to swap the control unit(s) on the outside of your old housings to the new ones. You won't need to code anything. I got my OE Hellas for the E60 from Amazon for a fraction of what BMW wanted for new ones. I haven't looked inside of the headlights on my E65 but I'm sure it's not pretty. Good luck.

[pbonsalb]

I patched up a 2008 E61 535xi headlight years ago and got a little more life out of it. Access is really limited so it is hard to do by what I would call a clean, through job. One light was later replaced due to an accident. Just had the other light fail and this time I bought a new Hella, which was almost $800 for the version for my car.