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[fudy]

ive had two headlights delivered in three days(tnx for the quick postage on the second one rob) both coming through the same delivery depot (ashton dpt), and both were damaged! the first one was smashed open on the bottom below the ballast, and on the other the right adjuster is broken. ive kept the adjuster of my original headlight so it looks like im gonna have to take one apart and fit a adjuster. is there any tricks to taking these things apart? one guy in the forum says he put his headlight in the oven

[hotel21]

Hairdryer/hot air gun to soften the black goo that holds in the glass to the backing.  Carefull and slow use of leverage around the edge will gradually release it.  Repair, then clean off as muchas you can before using fresh goo - sikaflex or similar - to replace. 

rethink ---- If you use sikaflex, it will be a lot harder to replace the adjuster again if it breaks.  It sticks like watsit to a blanket!!

[Welung666]

Hairdryer! It softents the sealant around the lense. Be very careful you don't break any of the tabs either. then carefully remove the indicator (2 torx screws on the end) and the silver reflector. Then it's a case of using an allen key to unwind the adjuster off. Re-fitting is the reverse 

EDIT: too slow as for sealant use black windscreen sealer, sticks like sh1t and never sets fully

[fudy]

rethink ---- If you use sikaflex, it will be a lot harder to replace the adjuster again if it breaks.  It sticks like watsit to a blanket!!

was thinking of using silicone to re-seal it?


what about the reflector that the adjusters are connected to, is there anything else to stop it being removed?

[Welung666]

rethink ---- If you use sikaflex, it will be a lot harder to replace the adjuster again if it breaks.  It sticks like watsit to a blanket!!

was thinking of using silicone to re-seal it?


what about the reflector that the adjusters are connected to, is there anything else to stop it being removed?

You'll see the clips when you get the lense off. Little white clips on the edge, just pry them out with a fingernail slightly and slide the reflector off one at a time Don't use (bathroom type) silicon as it sets solid, hence the suggestion of sikaflex. Given the choice I'd use POR15 as it never sets.

[Turk]

I've been working on three pairs of headlights in the last month. Used a hairdryer on first attempt but that took ages. Used a hot air gun (paint/varnish remover) on the other two sets and that was much quicker.
Got lens removal down to comfortably withing 10 mins that way.
Be careful with a hot air gun, don't get too close to the h/light and keep the gun moving back and fore, don't dwell one one spot.
Not used additional sealant on any of the three sets. There was more than enough sealant to just replace the lens without adding more. Give it a quick once over with the hot air gun to soften it a little, put lens in place and warm the area gently as you apply pressure to sealing edges.
Replace the metal clips and go over the sealing area once again with the gun to give it a final once over. 

Be carefull if wiping the reflectors, the mirror coating will rub off easily. Very light pressure and a soft clean duster only, don't use any cleaning products.

[Andy B]

......
Not used additional sealant on any of the three sets. There was more than enough sealant to just replace the lens without adding more.  ......

That's what I found! 

[fudy]

im suprised how easy the glass came off in the end, i just used a hair dryer and a old chisel. just to add to my luck both of the adjusters were broke in the end
but looking at theses adjusters it's easy to believe that it's a built in weak spot, the plastic's so brittle it's like bakelite ive asked mate to make me a new piece on his lathe tomorrow, so with a bit of luck im back on the road saturday