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-   -   Headlight removal issue, help please (http://986forum.com/forums/showthread.php?t=51755)

SmegHead 04-21-2014 12:52 AM

Headlight removal issue, help please
 
1 Attachment(s)
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

Nine8Six 04-21-2014 01:04 AM

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

Nine8Six 04-21-2014 01:08 AM

if you ever have to use the heat-up red option, watch for the carpet when your hex wrench goes off ;)

SmegHead 04-21-2014 02:08 AM

Thank you, like the idea. Do you think the epoxy will hold it ok?

Nine8Six 04-21-2014 02:19 AM

Quote:

Originally Posted by SmegHead (Post 396738)
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

Nine8Six 04-21-2014 02:49 AM

might be as simple as that:
http://bcfasteners.com/wp-content/up...rs-400x400.jpg

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 ;)

SmegHead 04-21-2014 04:03 AM

:)
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
http://986forum.com/forums/uploads01...1398081668.jpg

Nine8Six 04-21-2014 04:15 AM

(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?

SmegHead 04-21-2014 04:18 AM

Orient red apparently, my mates rib me it's pink.
Worcester UK

Nine8Six 04-21-2014 04:22 AM

Quote:

Originally Posted by SmegHead (Post 396757)
UK

I know mate, just pulling your leg ;)

BruceH 04-22-2014 07:49 AM

Quote:

Originally Posted by SmegHead (Post 396754)
:)
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
http://986forum.com/forums/uploads01...1398081668.jpg

That is an incredible color, very nice! Some penetrating oil may help. Good luck with getting it to move:cheers:

particlewave 04-22-2014 09:15 AM

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.

SmegHead 04-22-2014 09:48 AM

Thanks all, think I'll take a closer look and have a go at this weekend. I'll let you know how it goes.

BruceH 04-22-2014 02:32 PM

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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