Headlight not clipping in.
 

Boxster 986

Headlight won't clip in 100% secure.

I'm actually afraid that if I have to brake really fast, it may pop off.

All the clips are good. gets into place just fine, but the clip just does not clip in like the other side does.

What can I do?

Is it an aftermarket headlight? If so, it may not have the lobes that hold the locking bar in place.

Here's a Porsche light:
You may note three lobes:
http://986forum.com/forums/uploads02...1584652464.jpg

Some aftermarket headlights don't have them, and the bar slides down.

If you have had any body work done on that side recently, make sure there is nothing inside that is preventing the headlight from going all the way in. I had some bodywork done a few years ago and there was a metal tab coming out from the fender that was just a touch off and the headlight wouldnt go all the way in. Other than that, make sure all the tabs are going into their respective slots on the headlight tray. I also find it useful to use a 1/4 inch drive deep six point socket (it's the smallest one in my Harbor Freight metric set) with an extension and a ratchet, rather than the tool that comes in the tool roll with the car.

One of mine acted this way for no apparent reason once. Finally it just seated correctly. But I had the same fear that the whole assembly would just slide out when I applied the brakes. Oh, and I second the use of the socket rather than the official tool.

It may be these tabs

Yeah, that's it. I may have to try to build something up in that area.

So you have aftermarket lights, then? Me too.

Here's a pic of mine, it has no lobes either:
http://986forum.com/forums/uploads02...1584668122.jpg


Luckily, my car came with the original set in the frunk, so I was able to compare them and I noticed the difference.


I used the tool and wedged the lever against the body so it's constantly keeping back pressure on it. I also used a old caliper bleeder cap on the end of it so it won't scratch the paint (Not pictured). The tool stays in there permanently now and it works like a charm: (pic is upside down, sorry.)

http://986forum.com/forums/uploads02...1584668355.jpg


The interesting thing is that the other side seems to hold OK. Only my passenger side was the problem.

That's kind of a backwards fix. But if it works.
My drivers side is also fine.
I have 3 sets of old lights and none of the passenger side lights have tabs????

HAHA! Yes it is, but it works brilliantly. There's a small bulge in the carpet when you replace it, but all in all, not bad at all.:cheers:

I only have one aftermarket set, but if all of yours have tabs on the driver's side but not in the passenger side, then somehow it must be by design. The only thing I can think of is that the emergency release cable is behind the passenger light, so you can pull the light out and get to the cable. Not withstanding the fact that you can reach the cable from the wheel well, although not as easily. I actually moved mine to an easier to access location, so that'll never be a issue with me.

I rerouted my cable to be behind the cap for the tow bar.

That's a good spot. Many people move it there.

I'm just afraid if somebody has to tow the car when I'm not there, it will get ruined.

I doubt any tow truck operator will use it at all. They'll hook up underneath to pull the car onto the tilt bed.

Last guy who took it to the shop for IMS and Clutch asked if I had the tow bar, and used it, even though the car was running, and I could have driven it onto the flatbed.

Make your own lobes with tiny round head machine screws and nuts ;)