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Old 04-21-2014, 12:52 AM   #1
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Headlight removal issue, help please

Hi
I have a MY2003 986 with a problem with the headlight removal mechanism. I've had the car for about two years and never had to remove a cluster until today.
Upon trying to I found the hex attachment on the release bar is corroded and rounded off (picture attached), has anyone had a similar experience and could share the solution?
Thanks for any help
SmegHead
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Old 04-21-2014, 01:04 AM   #2
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1. clean off the rust of the hex the best you can (toothbrush ? dunno)
2. use an old hex key/wrench and epoxy the tip inside the hex
3. wait a few days (24~48hrs) for the epoxy to cure
4. spray wd-40 inside that thing, unlock your headlight
5. heat up the hex key/wrench RED to release the epoxy
6. remove your headlight

just a wild guess... not that I had to do it before

Luck mate
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Old 04-21-2014, 01:08 AM   #3
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if you ever have to use the heat-up red option, watch for the carpet when your hex wrench goes off
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Old 04-21-2014, 02:08 AM   #4
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Thank you, like the idea. Do you think the epoxy will hold it ok?
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Old 04-21-2014, 02:19 AM   #5
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Quote:
Originally Posted by SmegHead View Post
Thank you, like the idea. Do you think the epoxy will hold it ok?
nope, that is a lot of rust. Cheap finding out anyway and I can't think of anything else for the moment

wait a tad... some others will try to help you out that's 100% certain

Welcome to the forum
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Old 04-21-2014, 02:49 AM   #6
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might be as simple as that:


you just never know with these cars... it might be just as fast to remove a fender than to go hunting local stores for long nose wisegrip and epoxy resins
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Old 04-21-2014, 04:03 AM   #7
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I only wanted to remove them to polish them up a little. Polished the rest of the car over the last couple of days and fallen in love with it again.
Doesn't look bad for approaching 190k miles does it
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Old 04-21-2014, 04:15 AM   #8
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(special color!pfff ) seriously it is absolutely stunning. Looking just as new to me actually

like the wheels, and a huge fan of your pebble style driveway

where in the EU exactly?
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Old 04-21-2014, 04:18 AM   #9
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Orient red apparently, my mates rib me it's pink.
Worcester UK
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Old 04-21-2014, 04:22 AM   #10
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UK
I know mate, just pulling your leg
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Old 04-22-2014, 07:49 AM   #11
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Quote:
Originally Posted by SmegHead View Post

I only wanted to remove them to polish them up a little. Polished the rest of the car over the last couple of days and fallen in love with it again.
Doesn't look bad for approaching 190k miles does it
That is an incredible color, very nice! Some penetrating oil may help. Good luck with getting it to move
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Old 04-22-2014, 09:15 AM   #12
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That post is pretty far in there and tough to snap loose even in excellent condition.

My verdict: it's never coming out that way again. Your best bet is to try to gain access to the tray retaining bolts via the wheel well and/or underneath and remove the headlight with the tray.
Once out, it will be simple to separate the two and replace the tray with a new one.

I would do this at some point. Going to need change one of the bulbs eventually.
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Old 04-22-2014, 09:48 AM   #13
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Thanks all, think I'll take a closer look and have a go at this weekend. I'll let you know how it goes.
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Old 04-22-2014, 02:32 PM   #14
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In the long run, you are probably better off going with Particlewave's advice. Remove the wheel, then fender liner and remove the tray/headlight assembly as one. If going the other route, spray some penetrating lube now, some more each day, and maybe by the weekend it will be ready.
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