This document is a step by step explanation of how to remove and replace the headlight adjusters in the Euro headlights.
Parts needed to repair both headlights:
4 – 63 12 1 392 067 Adjusting Screws 2 – 63 12 1 392 030 Intermediate Piece
2 – 63 12 1 393 855 Gasket (for headlights, recommended)
2 – 63 12 8 124 448 Absorber (recommended)
Tools needed:
- Rotary Tool (Dremel)
- Flat bladed screw driver (little thin one and an average sized one)
- Wires cutters (to cut zip ties)
- Socket set (to remove headlights)
- Marker
- Needle Nose Pliers
- Philips Screwdriver
- Special Tool 63 0 020
- Most importantly… patience
1. Remove the headlight cover from the top of the bucket and unscrew the wiring harnesses to the headlights.
2. Mark the position of the nuts that secure the headlights with the marker and then remove.
3. There may be a nut that is attached at the back of the headlight assembly – remove.
4. Remove the headlight assembly by undoing the four bolts that were marked earlier.
5. There are three clips on the top and bottom of the headlight assembly that hold the front lens on. Pry these off with a flat screw driver.
6. At this point, remove and inspect the gasket that seals the lens to the bucket. They are pretty inexpensive to replace and this is an opportune time to do so.
7. Remove the two hinge bolts that the headlight pivots on. NOTE: There are little brass hats inset in the buckets – carefully remove and save them.
8. There is a clasp that holds the base of the headlight bucket to the assembly. Pry up the middle of it and slide the clasp off. This is a good time to inspect/replace the headlight absorbers. Cut any zip ties that hold the headlight wires to the assembly.
If your adjusters are like mine were in that they are basically non-existent, then the headlight assembly should push straight out. If any of the triangular pieces are still in tact, you will need to use special tool 63 0 020 to turn them 1/6 of a turn to unlock it from the housing. Once the inside of the assembly is free to move, push the grommet that holds the wires into the housing and feed the wires though.
9. With the guts of your headlight on the bench you can attempt to knock the old adjusters through (this did not work for me, however).
10. This is where the rotary tool comes in.
11. There are four grooves in the top of the white plastic – cut those down until you can se the black of the housing.
When it comes to removing the old adjusters, I found that the plastic was brittle enough that if I kept squeezing the white parts together that they would just break. If this does not happen for you, then you need to try and squeeze all the white pieces together so that the adjuster can be pushed through the housing.
12. Once all the adjusters are out, make sure the holes are clear of debris etc.
13. Prior to trying to installing the new adjusters, lube up the holes with something like WD-40. This will make it easier to seat the adjusters.
14. Installing the adjusters is a bit tricky as it is a very tight fit. The easiest way I found to reinstall them was to use special tool 63 0 020 to hold the adjuster and then use something flat against the back of it to push. Try and angle one side in of the adjuster and pry the adjuster over to the other side and try and get it to pop in. This part takes patience and holding your tongue the right way.
15. Once you have all the adjusters in, you will need to guide the headlight and adjusters back through their respective holes in the housing. Take your time to line up the triangular pieces with the holes prior to pushing it back together (ie. Check the orientation that the triangular pieces need to be in). It is very useful to have two people for this part. Once you have the adjusters through their holes, you will need to use special tool 63 0 020 to turn the back of the adjuster a 1/6 turn to lock the headlight to the housing. Make sure the adjuster is as far through the hole as possible prior to trying to turn them.
Installation is just the reverse of the removal. Don’t forget to:
- Zip tie the electrical lines to the housing
- Ensure that the rubber grommet that holds the wires in the headlight bucket is in it’s proper place (don’t want water getting in)
- Reinstall the brass top hats in the pivot bolts of the headlight housing. Be careful with these are they are very delicate.
- Install your new headlight absorbers, if purchased
- Install your new headlight gasket, if purchased
GOOD LUCK!
Tom ‘Wuffer’ Carter
Rob 'canadian8er' Scott
