Reinstalling headlight - having trouble
Thread Starter
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From: Santa Cruz
Reinstalling headlight - having trouble
I installed new lenses on my headlights. I gotta say, that was a very easy and relatively reasonable DIY that dramatically improved the appearance of my headlights. I guess after 20 years, the plastic lenses just yellow. So, all good removing the units and installing the new lenses. The trouble is getting them back in and locked in place. I don’t ever remember having a problem before. When I try to get the right side back in, it goes in fine, although doesn’t quite seat, which seems right, with the locking lever in the up position. Then when I try to lock by rotating the lever forward, I can only get 3/4 of the way down. And the light isn’t noticeably seating when it’s there. If I try to push past 3/4, the locking lever cams out of the light and the light unit comes forward.
Am I doing something / missing something obvious? Or is the unit misaligned? Or something else?
TIA
Am I doing something / missing something obvious? Or is the unit misaligned? Or something else?
TIA
RL Community Team
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Joined: Jul 2004
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From: Dallas, TX
I find that one needs to Teflon or silicone lube the headlight's pod tracks and rub a little lube around the socket seal for the electrical. This will make it much easier to seat the pod fully.
Andy
Andy
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From: SF Bay Area
I just did this on my 993 C4S. The new seal on the lens is fighting you. You need to push the unit back into the respective fender opening with some extra pressure. Once that's done and they're fully seated all should be well.
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Three Wheelin'
Joined: Feb 2013
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From: San Rafael, CA
I did this a few years back and inadvertently put the left lends on the right bucket and the right lens on the left bucket. Amazingly the lens will go on either bucket but then won't go back into their holes.......not saying you did this but it is possible.
G
G
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Thread Starter
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Joined: Nov 2008
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From: Santa Cruz
I never would have thought of this, but I wonder if it's possible. I replace them individually...so didn't pull both units at the same time, but I'm wondering if I inadvertently re-installed the new ones on the wrong side. Seems unlikely, but both sides were a problem and I seriously shoved both in place with my palm before trying to lock. The left side ended up locking, but the right side is stubbornly not locking and it's like I'm forcing it. If someone has a picture of the right side lens markings, both for that matter, it would be helpful.
Three Wheelin'
Joined: Feb 2013
Posts: 1,833
Likes: 148
From: San Rafael, CA
I never would have thought of this, but I wonder if it's possible. I replace them individually...so didn't pull both units at the same time, but I'm wondering if I inadvertently re-installed the new ones on the wrong side. Seems unlikely, but both sides were a problem and I seriously shoved both in place with my palm before trying to lock. The left side ended up locking, but the right side is stubbornly not locking and it's like I'm forcing it. If someone has a picture of the right side lens markings, both for that matter, it would be helpful.
Thread Starter
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Joined: Nov 2008
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From: Santa Cruz
For posterity - this was the problem. The driver side went back in basically fine...a little struggle, but not that big a deal. The passenger side WOULD NOT lock. I ended up getting it close and securing the locking arm with a zip tie for the last few weeks. I just got replacement bulbs (highly recommend the LED bulbs from Gert) so had to pull the headlight units out. As commented, the new seal was fighting me. Driver side went in a bit more easily this time and I REALLY shoved the passenger side in to seat it and got it to successfully latch / lock.
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Joined: Mar 2005
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From: Colorado
Make sure the pins are aligned on left and right sides with the channels. Then gently slide in and press with your palm firmly in the lower half of the headlight. If done correctly, lever will glide into place easily as you push.
Advanced
Joined: Jun 2024
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From: West Melbourne, FL
I installed new lenses on my headlights. I gotta say, that was a very easy and relatively reasonable DIY that dramatically improved the appearance of my headlights. I guess after 20 years, the plastic lenses just yellow. So, all good removing the units and installing the new lenses. The trouble is getting them back in and locked in place. I don’t ever remember having a problem before. When I try to get the right side back in, it goes in fine, although doesn’t quite seat, which seems right, with the locking lever in the up position. Then when I try to lock by rotating the lever forward, I can only get 3/4 of the way down. And the light isn’t noticeably seating when it’s there. If I try to push past 3/4, the locking lever cams out of the light and the light unit comes forward.
Am I doing something / missing something obvious? Or is the unit misaligned? Or something else?
TIA
Am I doing something / missing something obvious? Or is the unit misaligned? Or something else?
TIA
Drifting
Joined: Dec 2019
Posts: 2,621
Likes: 1,704
From: New Jersey
This is because the seal around the new lenses hasn't flexed into position yet. The old ones are "trained" and not fighting you.
Use a heat gun on LOW and keep it away from the seal several inches but keep going around it for a few minutes slowly/patiently. Do not over heat them or you will destroy them. They key is warm them up a bit so that when you push, they conform into the opening and you'll easily be able to lock them in place. Don't remove them for a few days at least so they conform to the shape permanently.
Warning, if you ruin the seal, you cannot buy the proper one. Porsche sells replacements but they switched them to some soft foam rubber crap that is a nightmare. They are nothing like the originals. If you buy the lenses, they come with the original style seals. So fair warning to use that heat gun sparingly or you'll be buying new lenses simply for the proper seals.
Use a heat gun on LOW and keep it away from the seal several inches but keep going around it for a few minutes slowly/patiently. Do not over heat them or you will destroy them. They key is warm them up a bit so that when you push, they conform into the opening and you'll easily be able to lock them in place. Don't remove them for a few days at least so they conform to the shape permanently.
Warning, if you ruin the seal, you cannot buy the proper one. Porsche sells replacements but they switched them to some soft foam rubber crap that is a nightmare. They are nothing like the originals. If you buy the lenses, they come with the original style seals. So fair warning to use that heat gun sparingly or you'll be buying new lenses simply for the proper seals.
Last edited by boomboomthump; Jan 29, 2025 at 12:23 AM.