What ever this small gauge wire is, it is near top of headlight. The wire plastic coating is coming off, leaving bare wire. Is there a repair kit for this or do we just need to break out the solder iron and heat shrink for this job?

 

Flaking headlight wiring is a known issue with the E60. Here is a thread with an extensive discussion about what to do about it:

https://5series.net/forums/e60-discu...rating-139655/

 

Thanks for pointing that out. I was talking about something waaaay more simple. Didn't realize there was a potential nightmare occurring inside the headlight!

 

As a sidenote, liquid electricians tape can be your friend. Paint each wire with several coats, one wire at a time, within the light housing. Time consuming but doable.

 

I saw someone mention that. never used it before. looks messy, but would prevent needing to cut wires. would be nice if there was some sort of heat shrink that you could slip around wires with out needing to cut the wires.

 

I just wrapped both wire bundles separately in adhesive tape. (Un)Surprisingly the tape has held up longer than the OEM wire coating!

 

Adhesive tape, as in Johnson & Johnson first aid tape?