Evening Peeps,

🥳 Happy New Year 🥳

My neighbour has a 2004 D2 and is wanting to replace the headlight on the driver side , he's not on a forum and asked me to upload a post on his behalf .

I've not yet managed to get round to help , but he saying one on the screws keeps spinning , how can he resolve this, I believe it's the ones on the top of the headlight he's questioning.

 

There is a brass thread insert into the top of the headlight housing plastic. The bolt freezes to the insert and it just spins. You will have to pull up on the bolt as it spins to remove the insert the bolt. If you are reusing the same headlight you will need to epoxy the insert back into the housing.

 

On our 04, there are two external torx bit bolts holding top of plastic housing, if you don't have an external torx bit...a 10mm socket will do the job. Our 03 has 10mm headed bolts. You need to remove the grill, three plastic fasteners along top of grill must be removed, then pull grill straight up and wiggle it out of bottom guides (two plastic guides, which have to short pieces of hose on them). Once grill is removed along inner portion of headlight assembly (towards grill) you will see a little plastic door, just below the horns, behind that door you find a 25mm torx bit screw holding headlight housing, remove. Once the two upper torx and small side torx are removed, wiggle headlight assembly out, you may need to pry between fender and headlight bucket, gentle with plastic tipped tool too get outer headlight assembly guide to slide out of fender mounting hole. Unplug headlight bucket and remove plastic cap on headlight bucket, covering light you desire changing. Me, l usually change them all while l have them out.

 

Cheers Guys,

He has another light to go in as the one he’s trying to remove is full of condensation. I’m not familiar with the light unit is it the screws on top of the light which would be spinning?

Anyone know the part number to get 2 new bolts / screws ?



I’m assuming these are the screws that hold the lamp in place ?

 

It's the two directly inboard - star shaped. 8mm 12-pt will remove them, also there is a horizontally oriented torx screw that is accessible once the grille is removed.

 

K PacoPico , 👍🏽. So the 2 the chap is pointing at are fir what exactly ?

 

Those two screws are for adjustment/alignment of beam(s). The two larger torx bits are the ones you're after.

 

Ok thanks , is that what was mentioned in the earlier post about being stuck and have to be snapped off ?

 

Not sure what post you're talkindg about, as far as snapping something off?

It's pretty easy method, just remove the two fasteners circled, then the grill, then the small 25mm torx fastener behind plastic door...and pull the head light assembly out.

 

Hey , the bolts keep turning and not coming out, solution ?