Recently went to replace the low beam bulb on the Disco and found every single bolt for the housing stuck like you would not believe. After soaking them in penetrating oil for a week with no avail, I began to devise another plan (yes...a week with only one headlamp). Trying to put heat on the bolts was a no go because of the proximity of all the plastic.

Final solution.....drilled a tiny hole in the middle of the bolt about a half inch down. Stuck my soldering iron in the hole for about 30-45 seconds...heated the entire bolt without damaging anything else....bolts came out with no further issue.

Conclusion--Soldering iron is a good way of applying significant heat to a very precise location.....

Hope this helps someone.

 

You don't remove the adjuster bolts just to replace a bulb, you pop the hole head light assembly straight out the front and the bolts will come of the nylon holders on the head light.

 

I just spit out my coffee....are you serious?

 

I thought I was pretty clear but I'll say this again. Once I remove the grill I started to remove the three screws that hold the headlight housing in place. No I did not drill out the adjustment screws....I removed the screws that hold the housing to the core support. Just like the owners manual states.

 

They are just jealous of our 2003-2004 style headlights.

 

PHEW, I was going to say!!

Raul, I suggest next time, you tell everyone the year of your Disco, or better yet, put it in your signature, as the 94-02 is apparently MUCH easier to deal with than the 03-04 style, and I don't think drilling would ever be necessary to remove the headlights.

You guys and your fancy-pancy hard to deal with headlights!

 

Drilling shouldn't be needed, but a screw driver is. I guess the screw wouldn't cooperate for him.

 

Try Deep Creep by SeaFoam. It helped me get all the stud bolts loose when taking down the Y pipe. Also putting a #3 philips bit in a socket wrench may have helped you bust them loose. I've had mine off and on so may times when doing my HID headlight mod, I can do it with one eye closed.

 

On mine, the head of 1 bolt is broken, I guess it was not cooperating with somebody, the side that I needed to open to replace the bulb was not too difficult to open.

 

Yeah I guess I wasn't as specific as I thought. I knew the 03-04 had different headlamp but didn't know that were that different. Just another reason to be jealous of the older Disco's (I have an 03, so no center locking diff). Either way the final point I was trying to make was a soldering iron can, unbelieveably, be useful in removing smaller bolts (when heat is needed).