My Headlight Adjuster replacement Story
It was not difficult but it took alot of patience and finess. Having read all sorts of posts and seeing some pdf files, I tried the bake method. I beleive the sealant that was used is some sort of butyl that is used to seal windshields in and it did not take long for me to figure that I had to do something else. I saw one post on this forum where someone had cut the clear lenses off with what looked like a chainsaw. I knew that was not the way to do it.
I removed the headlamp assy's.
I removed all of the bulbs.
Then I removed the rubber boots (be careful because they tear easily, ask how I know this)
The projector lamp adjuster was fairly straight forward. I could see the adjuster. I removed the old peices ( that took the longest time) then took a T-8 torx bit and removed the socket that hold the ball. Then I installed the new adjuster. One key point here is not to snap the ball in the socket yet.
Here is where the patience part comes in. On the high beam adjuster, I marked out a 2" x 2" square on top of the housing, just inside of where the adjuster tracks are. I took my trusty dremel tool with a cut off wheel and cut a window in the housing. I caution you to take your time! Beneath this window is the fiber optics receiver and cabling. Only cut deep enough to get through the 1st layer of plastic. I was able to see everything and perform the repair on the high beam adjuster.
To close the window I had cut, I used a plug that is for 2" square tubing. I had to trim it so that it would sit flush on the housing. I used clear silicone to seal it, but I suppose you could use epoxy also.
I would post pictures but I do not have enough posts yet to do so. Maybe I can make a DIY when the time comes, if anyone is interested...
I have been an E39 owner for 4 months now and really enjoy this car. I thank everyone who contributes to these forums because it has helped me remedy the few problems I have had.
Thanks!
raise::rollsmile:
