Need help... - 986 Forum - The Community for Porsche Boxster & Cayman Owners

axp2948 · 09-24-2012, 03:29 PM

Hi guys,

So as I was attempting to remove my headlamp assembly over the weekend to change out a bulb, the hex bolt that i was trying to rotate broke off from within the car. I am unable use the tool to remove the headlamp anymore. I'm not sure what to do at this point, any help would be much appreciated!

-Alex

Deserion · 09-24-2012, 04:54 PM

Have you tried to use a deep-well socket/ratchet instead of the tool from the trunk kit? I've noticed the included tool oftentimes fails, while the socket will not.

thstone · 09-24-2012, 06:10 PM

The factory tool rotates the small arm that locks the headlight assy in place. Try to figure out another way to rotate the arm. Its hard to give you any specific suggestions without knowing exactly what part broke and exactly where it broke.

axp2948 · 09-24-2012, 06:35 PM

the entire lock hex rod is broken where i was rotating to release the headlight assembly. is there any way to push the headlight out from removing the wheel liner?

particlewave · 09-24-2012, 07:29 PM

Oh, you're in trouble. If you can't rotate that bar, the headlight is locked in place. I can't think of any solution.

axp2948 · 09-24-2012, 08:18 PM

yeah thats exactly the issue im in right now...

particlewave · 09-24-2012, 09:08 PM

Okay, so I felt kind of bad about my completely useless post. I popped my headlight out to have a look for you. The fender and headlight well are all one piece spot welded together. If you can remove the fender and gain access to the underside of the well, you can then detach the plastic tray from the well, giving you access to the locking bar.

That's a lot of work to change a headlight bulb, but you'll be able to change the locking bar too.

axp2948 · 09-24-2012, 09:46 PM

thank you so much for that information, your post was not useless at all, you helped me clarify exactly what the problem was. I will try your advice to see if I can remove the fender to pop it out that way.

tricolour · 09-25-2012, 01:29 AM

Quote:

Originally Posted by particlewave

Okay, so I felt kind of bad about my completely useless post. I popped my headlight out to have a look for you. The fender and headlight well are all one piece spot welded together. If you can remove the fender and gain access to the underside of the well, you can then detach the plastic tray from the well, giving you access to the locking bar.

That's a lot of work to change a headlight bulb, but you'll be able to change the locking bar too.

Good post PW and a nice gesture.

Spinnaker · 09-25-2012, 02:14 AM

This diagram might help you figure out what is involved.
Porsche Boxster Headlamp Parts

jerry430 · 09-25-2012, 04:35 AM

I had the same problem - couldn't get the assembly out no matter what I tried.
I was able to access it through the fender well and open the cover door to replace the bulb without ever removing the assembly. Took about an hour.

axp2948 · 09-25-2012, 10:24 AM

Thank you all. I will try this on the weekend and let you guys know what happens.

Jittsl · 09-25-2012, 11:59 AM

I've also accessed the bulb from behind by removing the fender lining before I knew how easy it was to remove the headlight (my wife often suggests I read the instructions but it just ain't in my blood). The fender lining is self evident and easy. And if the headlight stays in forever - so be it. As far as I know the only reason to remove it is to replace globes and you will have just done that.

Bruce Wayne · 09-25-2012, 12:21 PM

another option may be to drop the front PU off the bumper/nose and get a long screwdriver under the lamp assembly to get on to the bar.

in effect the headlamp assembly is held in place by the cam action on the bar, if you can un-click that, the headlamp assembly should just slide out on the runners.

NB: i'm just throwing this out there an option as I have not tried it

milliemax · 09-25-2012, 03:34 PM

Quote:

Originally Posted by particlewave

Oh, you're in trouble. If you can't rotate that bar, the headlight is locked in place. I can't think of any solution.

Danger, This is pretty mean of you not to "Chime in "about you know what !!!! You bought a can and have been very silent. Shame....... Shame on you !!!! Please help these nice members. Alot of us depend on YOU !!! MAX

axp2948 · 09-25-2012, 05:16 PM

I really appreciate all the suggestions provided in this thread.

Bruce Wayne, what do you mean the front PU? what is PU? excuse me if I'm new to this, are you suggesting i take off the entire front bumper cover?

Thanks,

Alex