Thread: all years Euro glass headlights
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Old 09-25-2018, 10:37 PM   #213
paul somlo
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A few posts back, I asked about wiring harnesses. I did some research, and just wasn't hearing very good things regarding the quality of commonly available 9005/9006 pigtails. And at $3.99 for two pigtails (including shipping), I was a skeptic. So, I decided to make my own, using OEM (Aptiv - formerly Delphi Packard) parts, seals, terminals, and TPA (terminal position assurance - which keeps the terminals from backing out).

It was surprisingly difficult to track down part numbers and even identifying the connector family (Metri-pack 280) was a challenge, not having any experience with automotive connector systems. I found two sources - Ballenger Motorsports and Mouser. Ballenger's pricing is fairly high, but they do provide the option of doing the crimping for you, providing a completed pigtail. It appears they use OEM parts, as well. As an aside, what's typically referred to as a 9006 female connector is Aptiv PN 12059181, while the 9005 is Aptiv PN 12059183.

I chose to order from Mouser, and do my own crimping. I crimped directly to the round OEM connector that Kitty provided, adding wire only to provide a separate ground to each pigtail. For the ground, I soldered the three wires together and used an uninsulated crimp for insurance, finishing with a closed end heatshinkable cap. My preference would have been something like this: https://www.electriduct.com/HydraLin...onnectors.html but I couldn't find them locally, and I didn't want to incur any more shipping charges. The two additional wires can be 18 AWG.

Here's a parts list, from my Mouser.com invoice, cost was about $14 for the four pigtails, and about $5 economy shipping, crimpers were about $23:

12084166-B Male Connector, mates with 9006 female, qty 2
12084167-B Male Connector, mates with 9005 female, qty 2
12059185-B TPA, qty 4
12048159-L Male Terminals, qty 12 (min)
15324985 Cable Seals (purple), qty 8
ES-CAP-NO.2-B9-0-30MM Heat Shrinkable Cap, qty 2 (choose dia. according to your wiring method)

Crimpers: SG Toolaid 18910, cheapest price was ebay, through JB Tool Sales: https://www.ebay.com/itm/SG-Tool-Aid...72.m2749.l2649
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Last edited by paul somlo; 09-28-2018 at 11:57 PM. Reason: add PN for female 9005 and 9006 connectors
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