Headlight assembly removal - 986 Forum - The Community for Porsche Boxster & Cayman Owners

Rob175 · 04-01-2015, 04:09 PM

I was attempting to remove the headlight assembly on my 98' Boxster (to replace a bulb). I did this once before, a number of years ago, but now I'm having a terrible time. The "wrench" that comes in the tool kit just doesn't appear to fit into the nylon receptical fitting in the car's fender hole. It looks like the kit's hex wrench end is bigger than the nylon female fitting, in the fender so it's not turning it.

So I'm really baffled since I know I once removed the assembly. Any ideas? (the "wrench" in the kit is a two part piece...the wrench portion and a pivoting handle... at first I thought I was using the wrong one, but it's the only one in the kit)

What am I doing wrong? Ideas?.... seems nuts to go to a dealer just to do something I did once before.

tommy583 · 04-01-2015, 04:24 PM

You have to pull out the black rubber plug behind the carpet to remove the headlight. The little black flaps have the headlight adjustments behind them. I think this is why you are having a hard time.

crooster · 04-01-2015, 04:27 PM

My supplied wrench had a crack in it which caused it to spread and lose grip. Use a socket instead and make sure you are turning the right way. It's covered in the owners manual.

tonichristi · 04-01-2015, 04:34 PM

If you'd stop trying to stick the removal tool in the adjustment NYLON HEX, you'd be fine. You're putting it in the wrong hole, as said above.

tommy583 · 04-01-2015, 04:58 PM

If you end up using a socket, a 5mm should be the correct size.

clickman · 04-01-2015, 05:11 PM

I suggest you get a manual.

KevinH1990 · 04-01-2015, 05:57 PM

https://www.youtube.com/watch?v=D65x8G1f6AI

Rob175 · 04-02-2015, 04:43 AM

THANKS GUYS!..... now I really feel "stupid". You all are 100% correct I was using the wrong access hole....dumb, dumb, dumb! I suppose I should stick to waxing, cleaning and detailing....lol. As Dirty Harry said: "A man's got to know his limitations"

Thanks again guys!

R

steved0x · 04-02-2015, 05:14 AM

We've all started somewhere, the Boxster is the first car I have ever worked on.

Here is a great resource: The 101 Projects for the Boxster by Wayne Dempsey of Pelican Parts, the sponsor for this board:

101 Projects for Your Porsche Boxster

You can download an owner's manual here (and plenty of other places too) if you don't have one:
http://jdmfsm.info/Auto/Other/Porshe/Owners%20Manuals/porsche_boxster_owners_manual_2000.pdf

The Bentley manual for the Boxster is very useful as well and they come up on ebay and on this forum from time to time:
Porsche Boxster, Boxster S Service Manual: 1997-2004: Bentley Publishers: 9780837616452: Amazon.com: Books

Good luck and have fun!

Steve

Rob175 · 04-02-2015, 09:53 AM

Thanks.....and fortunitely, the "wrench" didn't fit and turn the adjusters or Lord knows where my lights would be pointing today!...LOL

tommy583 · 04-02-2015, 11:23 AM

Quote:

Originally Posted by Rob175

THANKS GUYS!..... now I really feel "stupid". You all are 100% correct I was using the wrong access hole....dumb, dumb, dumb! I suppose I should stick to waxing, cleaning and detailing....lol. As Dirty Harry said: "A man's got to know his limitations"

Thanks again guys!

R

Glad we were some help to you