S2/Turbo front lights: just need a moan...

[sr.944man]

Hi All,

Having studied the forum archive and seen the well-documented issues with dismantling the combination fog/side/aux headlight unit, I was prepared for trouble. Just as well, cos I think I got the lot!

So far, I've only gone to town on the N/S unit. The four securing screws were all knackered, tried drilling the heads off the inboard, more accessible ones. Heads removed, still no sign of movement, so moved to next stage.

Up on ramps, batwing off. Unplugged wiring and removed 3 x 8mm nuts behinhd bumper, removed entire light unit to bench - no problem. I then set to trying to get the screws out by drilling from the rear, through the brass inserts. That worked eventually - unfortunately I cracked the lens in the process. D'oh!

While considering my options for the damaged unit, I thought I'd whip out the other one and get some Plus-Gas on the fasteners. (For reasons I still haven't fully figured out I had taken the car off the ramps and put it back in the garage before I got that bright idea.) So groping behind the bumper I encountered the cooling loop for the power steering hydraulics. I'll have to get it back on the ramps for a proper look but I'm guessing the bumper will need to come off to release the O/S light unit.

I really just wanted to change a sidelight bulb......

So the dealer list price for the complete unit without Club discount applied is £318 each side. I'm pretty sure that is what is going to be the preferred route for the N/S. I might still save the O/S one... but I WILL be using stainless screws on whatever ends up going back in.

Any helpful suggestions, hints/tips, sources for parts or just sympathy welcome!

 

[GlennS]

So the dealer list price for the complete unit without Club discount applied is £318 each side

I feel for your problems. Out of interest, I was quoted £250 ea two weeks ago by OPC Hatfield, still eye watering but better than £318. I declined as mine were merely "a bit scruffy".

 

[zcacogp]

Drilling those screws out is a pain but the correct way forward. I used a small bit in a pillar drill, and once you had drilled down the middle of the screw then the heat and vibration was enough to get it loose. And, yes, stainless screws (M4 standard pitch IIRC) to replace it is definitely the way forward. (I smeared mine in renolit - waterproof grease - before putting them in).

Cracked lenses can be patched up very well indeed if you put some clear araldite on the back to hold the crack together (it's a very similar refractive index to the glass so invisible once on there) and some helicopter tape on the front. Glue and tape will give you change from a fiver, and is worth a pop before shelling out £250/£318 on a new unit. One of mine was badly cracked but, having been repaired using this method, you really would struggle to spot it 4 years on - even if you knew what you were looking for.

Once you have taken it apart and re-assembled it with stainless screws it should be good for years.


Oli.

 

[Richair]

Reading this has ruined my evening and I feel your pain!

I had no idea they were such a problem until this afternoon I thought I'd whip off a lens to see why my lights are dazzling oncoming drivers, only to be confronted by a multitude of completely rusted screws and no hope of removing any of them. Marvellous and possibly another expensive and frustrating job on the list... Just two stainless screws would have been enough Mr Bosch! Grrrrrr

 

[jonnyporsche]

I understand your pain. Fortunatly the previous owner of mine had fitted new light units with covers (a very sensable thing to do considering the cost) but had not replaced a dodgy houseing which had been bodged to secure, housings are like rockinghorse muck secondhand but I found two on ebay from America. Rebuilt the units and used stainless screws and grease on everything, worth doing right []

 

[944Turbo]

Berlyn were the cheapest last time I bought one, still around £180 though and that was a few years ago,
Tony

 

[pauljmcnulty]

You can get replacement lenses for under £200, the £318 with discount is probably the whole assembly?

 

[944Turbo]

Oh yes Paul is right, you get all the bulb holders and bits with the lenses but not the back panel my price was without the rear piece.

 

[sr.944man]

Thanks to everyone for all the suggestions (and sympathetic remarks!) I'll get back at it when the weather dries up again...

Cheers!

 

[GlennS]

ORIGINAL: pauljmcnulty

You can get replacement lenses for under £200, the £318 with discount is probably the whole assembly?

The £250 ea I was quoted by OPC Hatfield was for the whole assembly as I was advised by the bodyshop that attempting to "just replace the glass" was fraught with difficulty.

 

[zcacogp]

Bodyshop is definitely pulling your plonker my friend. You need to take the glass off to replace the unit, and comments like that from the bodyshop make me wonder whether they know what they are talking about.


Oli.

 

[944Turbo]

To be fair, the bodyshop probably don't want to mess around drilling out screws through glass and its associated issues and by the time they have the hours will add up to getting a whole new unit anyway, so full new unit is probably a better bet than just the glass in this case - DIYing there are more options available if your time is 'free'

 

[zcacogp]

Ah, Sorry, I thought Glenn had already taken his apart.

If not then, as you were.


Oli.

 

[Richair]

Think I'll be tackling this one later this week so we'll see what horrors I unleash... Not a job I'm looking forward to though and this one could get expensive!