Just bought a used 97 SE. It appears as though a bulb was broken in the left headlight assembly, or whatever you technically call it. There is broken glass and a white powdery substance on the inside of it, and it is noticable because it's not nice and clear like the other one.

I gave it a look and couldn't tell immediately how to get it out or disassemble it. There are two clips on top and removing them appeared to do nothing. Haven't had a chance to pick up the Haynes manual yet and not sure if this would be in it anyhow. Any hints appreciated on taking it apart or at least getting it out so I can clean it.

 

Sorry, I don't know how to fix it, but I would appreciate it if you could eMail me the directions if you get them. I just got a new headlight and I want to replace it. I know it is a strenuous process and you have to remove the grill to get to it. Just trying to help .

 

How ironic...I just did this today....passenger headlight.

The best way to do it is to remove the headlight from the chassis, remove the "glass", and clean it.

To do this, the grille and the parking light must be removed.

I bought a Chilton manual, and it was completely wrong on how to do this.

Anyway, you remove the grille by using a flat-head screwdriver to unsnap the brackets holding the grille in from behind the grille. Just push downward and pull (not too hard) on the grille. The bottom clips come out on their own with a little force, and don't need pressure from the screwdriver.

Then you need to remove the parking light...unscrew the screw on the top-left (for passenger side) of the headlight.
Then reach inside and push the parking light forward.

NOTE: The parking light is screwed in towards the front of the light at the back side of the parking light.

I could not figure out for the life of me how to get it undone, because the Headlight is in the way....I ended up just getting ****ed and snapping the plastic off....It seems to have been a redunant attachment anyway, and the screw on top seems to hold it in quite firmly by itself.

I know it was kind of ghetto, but it's the back side of the parking light, noone will ever see it anyway. If you figure out how to get it undone without snapping it off, let me know. According to the Chilton's manual, that hsouldn't be there....But that's why Haynes is better.

Next, after the parking light is removed, you will see two phillips-head 10mm hex screws holding the left side of the headlight in. Undo these.

On the other side of the headlight are two more bolts that must be undone with a 10mm ratchet also. The bottom bolt is covered partially by the A/C steel hose. Don't disconect this hose!!! You will lose all your freon!! (I know this NOW) <grin>

You have to get a little inventive on the bottom bolt...use a long extentian on a ratchet, or if you don't have that, a long ratchet-screwdriver tool and a pair of vice grips to turn it with force.

After you get the headlight out, take it inside, and use a heat gun to heat up the area around where the headlight lense meets the plastic, always moving the heatgun around the lense edge so as not to heat it up too much

(check out "Making A.E. Style Healdights on Maximadriver.com "How2")

Then use a screwdriver to SLOWLY pry the lense from the plastic. This is the reccomended way, but takes a LONG time and alot of patience.

I found a better way.

Simply heat your oven to 250 degrees and pop the headlight in there for 5-10 minutes. Use oven mits to hold it and pry it with a screwdriver...the lens will pop right out...no heat gun needed!!! This worked great for me, but I don't know what other people will think.

Clean it quickly, and while it's still hot, put the lense back and use a little silicone sealant to make sure the seal is nice and waterproof. (see the maximadriver.com "how2" again)

do everything in reverse to get it back on.

Sorry my instructions are so detailed, but I wanted to make sure you got everything.....it's a pain in the a**.

IanS

 

Oops.

Remove those metal clips before seperating the glass, of course...a flathead screwdriver works fine.

Just push them back on when done.

IanS

 

i had a headlight bulb bust on the passanger side....ill tell you ghetto.....take a coat hanger and straighten it....bend it in half...wrap a rag arond it and hold on to the rag....then with windex on the rag (after bulb is removed) wipe down the inside....now thats ghetto....lol but it worked

 

I actually tried that...no luck....

I couldn't get the left side of the lens...coudln't contort like that....heh

Good job, tho!!

IanS

 

No, thank you for going into so much detail. I just got the Haynes manual last night. Using that and your instructions, I'll try the removal tomorrow and report if I find anything different.

 

The one thing I didn't mention is that while trying to get to the difficult bolt, I unbolted what I thought was the Radiator overflow hose to get to it.

It turns out that is part of the A/C system....Freon went EVERYWHERE.

Cost me $189.00 to refill the A/C and fix the broken seal.....

Live and Learn.

IanS

 

I removed the houing by taking out the four 10mm bolts mentioned in the earlier post. I then mixed dishwashing liquid with hot water and put the mixture in the headlight(after removing the broken glass by shaking it out) then just mix the water around like you're fixing a drink and let it dry in the sun or use a drier. This worked great for me and I didn't have to remove the glass or stick anything like a stick or a coat hanger in the light assembly.

 

Yeah, I tried that first.....

Didn't work because it's been too long and the film was caked on and wouldn't come off by just swishing Simple Green and Windex in there....

That's when I took it apart.

Ian

 

The easiest thing to do is to go on ebay and buy a brand new headlight assembly for like $ 60.00. The just switch it. Not only will it solve your problem , but you will have a brand new headlight without the sh*t that gets on it from driving.

 

Laugh....then you have a "brand new" headlight and a headlight that's been used....still causing the problem of having one brighter than the other!!!

Besides, what would be the fun in just replacing it!?

 

What i mean is that you would replace both and then you would have 2 brand new headlights that look equally clean.

 

The cheapest, even on Ebay, I have seen is $80 for one...getting two new lights would cost $160.00....which is actually less than what I spent replacing the freon I lost....laugh.

IanS