leeshephard

Whilst checking my oil cooler ballast resistor last night, I popped out the headlamp to see if it had been removed (open circuit reading from relay contacts) and now I cant get the damn thing to fit flush at the top...there is a small gap between the rubber seal and body.

I have pushed pretty hard on it but it wont stay in...is there some trick to getting these things in?

while the lamp was out I did notice that the metal 'rail' was a bit rusty, could this have anything to do with it?


any help appreciated

Thanks

Ed Burdell

The connector plug at the top outer bout of the headlight assembly has to be aligned correctly to make the electrical connection and to allow the headlight to fit properly.

I'd finesse it, though - you can easily break a plastic guide pin off if you use too much force. As I did!

leosayer

You shouldn't need to push at all, the metal clip should pull it into place.

There's probably something inside the cavity that is preventing it fitting into place.

V

+1. You should need to use too much force. While you are at it you could spray inside the conector with contact spray and put some grease on the outside to make it slide easier. But check so that it is properly aligned before applying force.

David in Chicago

Be absolutely sure you've moved the release lever fully to the "open/release" position. Whenever I've had trouble with mine, the lever's been just short of "full open," which blocks the assembly from seating fully. As Leosayer says, it should fit pretty easily.

Regards to all.

leeshephard

thanks for the replys guys, I'll take another look tonight!