Splicing Headlight Wiring Connector Issues

Discussion in 'Prius v Main Forum' started by Gahzoo, Oct 27, 2025.

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  1. Georgina Rudkus

    Georgina Rudkus Senior Member

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    From what I see, a ring or any other v screw or 1/4 inch spade terminal can be used to function the same way as the expense and hard to get Toyota specialty butt connectors.

    Basically, strip the ends of the wires to be spliced.

    Thead an appropriate sized adhesive heat shrink tubing over one of the wires.

    Clip the end off of the terminal to form a barrel.

    Thread the barrel over the same wire.

    Twist the wires ends together end to end.

    Coat the twisted wires with gray anti oxidation compound available in the electrical department of any hardware store.

    Move the barrel connector over the exposed twisted wires and crimp securely.

    Place the heat shrink tubing over the connection and heat.
     
    #21 Georgina Rudkus, Nov 6, 2025 at 4:25 PM
  2. ChapmanF

    ChapmanF Senior Member

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    "Butt connectors" aren't what the Toyota-spec connectors are. The Toyota ones make parallel splices, not butt splices.

    If you were going to cut up a terminal and use its barrel to make a parallel splice, I guess you could also cut a common butt connector in half and use its halves to make two parallel splices.

    The thing is, most of those ring or spade terminal barrels that I've seen are the open kind, metal that's stamped so its ends curl around and meet to make a barrel shape, but the ends are just next to each other. I think (though I haven't looked at one in a while) that the favored parallel crimp sleeves are unbroken tubular barrels.

    And you'd have to improvise on selecting the size of connector, because you'd be asking the barrel sized for one wire to go around two wires and end up making a proper crimp.
     
    #22 ChapmanF, Nov 6, 2025 at 5:15 PM
  3. Gahzoo

    Gahzoo Junior Member

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    Genuine Toyota pigtail harness is what should have heen installed.
     
    #23 Gahzoo, Nov 7, 2025 at 1:57 PM
  4. Gahzoo

    Gahzoo Junior Member

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    Update #2
    - car scanned for codes at shop.
    - yes, some stores codes retrieved.
    - nonetheless, car now is running perfectly. No issues since yesterday.
    - mechanic said the headlight is the issue as it is strictly connected to the 12v battery.
    - I'm at a loss at yo what may have occurred at the initial shop which did the headlight repair to initiate the various electrical/code issues I was experiencing, and how using another scanner unintentionally, cleared up the existing issues? I am absolutely perplexed at this point?
    - also, what scanner is recommended to purchase (preferably one that reads hybrid cell voltage)
    Thank you
     
    #24 Gahzoo, Nov 10, 2025 at 8:54 PM
  5. Brian1954

    Brian1954 Senior Member

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    So, are you going to tell us what the stored retrieved codes are? That information would be very helpful.

    I recommend an Autel AP200 for a scanner. It is an OBD2 Bluetooth dongle, and you install an app on your phone. It costs about $60 on Amazon. Read post #1 and then scroll down to post #37 in this thread, https://priuschat.com/index.php?posts/3246758
     
    #25 Brian1954, Nov 10, 2025 at 9:45 PM
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