S-Class (W220) 1999-2006: S 320 CDI, S 320, S430, S 500, S 600

Replacing Headlight harness

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Old Oct 15, 2024 | 01:39 PM
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Original_Idris's Avatar
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S55 AMG (W220)
Replacing Headlight harness

The "tab holders" on my old connectors for my headlights (Plug 772725) broke.
I went to the dealership and ordered new ones ($10).
However, to buy new pins, would cost $20 per pin or $240 for both plugs, which I just find to be too much.

Problem is I have to remove the pins from the old plug and then install them into the new one.
Does anyone know how to do this?
I have removed the light grey "locking connector" but they are still being held in place. I can't see anywhere to insert a pick to get the pins out.
I'm doing the classic Youtube searching for this type of project.
I'm hoping I'm not the only one to do this and someone can help me out.

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Old Oct 15, 2024 | 02:35 PM
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Original_Idris's Avatar
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S55 AMG (W220)
Figured it out.
I'm going to keep the thread on here incase anyone runs into this problem.

But the solution was a bobby pin. I cut the two round ends off. Straighten out the side that has ridges (squeeze in needle nose piers)
Then carefully insert above and below the pin.
Once in, take the same needle nose and push in about another 1/16-1/8 of an inch. hopefully it clicks, but not always.
Then with another set of piers, pull the wire out the back. It takes a surprising amount of force because of the water seal.
Biggest issue was not dropping the bobby pin when the wire came out the back.

Anyway, once I got that figured out, it only took about 30 minutes to do both connectors. Just takes patience....lots of patience.
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