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knw911
Trainee


Joined: 19 Oct 2016
Posts: 61



PostPosted: Sat Dec 15, 2018 5:05 pm    Post subject: stuck headlight Reply with quote

like many 996's of this vintage, my headlights have yellowed a little. today i chose to tackle them with my DA polosher.

thought it would be easier to do them on a bench... so popped out the passenger side and went to work. all good....however,

went to the drivers side and simply couldnt get it out the car. the retainer bar seems to be spinning and / or the tool spinning on the bar.

any help or ideas folks??
 
  
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Robertb
Dijon


Joined: 01 Sep 2003
Posts: 7059
Location: South Oxfordshire

2002 Porsche 996 Carrera 4S

PostPosted: Sat Dec 15, 2018 5:22 pm    Post subject: Reply with quote

Have you tried a proper (if I recall right) 5 mm socket? The one in the tool kit is not great.

I think it’s a solid bit of metal, so not much to go wrong with the retaining bar.
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knw911
Trainee


Joined: 19 Oct 2016
Posts: 61



PostPosted: Sat Dec 15, 2018 5:36 pm    Post subject: Reply with quote

Robertb wrote:
Have you tried a proper (if I recall right) 5 mm socket? The one in the tool kit is not great.

I think it’s a solid bit of metal, so not much to go wrong with the retaining bar.


will try that.. cheers!
 
  
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Paynewright
Monza


Joined: 17 Apr 2018
Posts: 173
Location: Nr Lutterworth Leics


PostPosted: Sat Dec 15, 2018 7:09 pm    Post subject: Reply with quote

The tool doesnt work on mine - I use a 5mm deep socket 1/4” drive. Now in the tool kit with a T bar and extension.

Ian
 
  
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asterix_the_gaul
Barcelona


Joined: 20 Dec 2008
Posts: 1263
Location: Cheshire

1999 Porsche 996 Carrera 2

PostPosted: Sat Dec 15, 2018 7:13 pm    Post subject: Reply with quote

I really struggle with the passenger one out, it's easy to get the tool in the drivers side, the passenger side plastic hole surround thing is just off by a mm to unless I really force the tool in dead hard it spins as its not engaged on the hex head.
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knw911
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Joined: 19 Oct 2016
Posts: 61



PostPosted: Sat Dec 15, 2018 7:30 pm    Post subject: Reply with quote

will try a 5mm tomorrow ... thanks guys
 
  
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knw911
Trainee


Joined: 19 Oct 2016
Posts: 61



PostPosted: Sun Dec 16, 2018 1:09 pm    Post subject: Reply with quote

so tried the 5mm socket, same problem in that it isn't releasing the headlight. could the head light have been incorrectly seated last time its been put in? also, the 5mm socket is now stuck (sure will come off with some pilars).

also not great pic, but photo of the polished vs non polished headlights for those interested.
 



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Paynewright
Monza


Joined: 17 Apr 2018
Posts: 173
Location: Nr Lutterworth Leics


PostPosted: Sun Dec 16, 2018 1:38 pm    Post subject: Reply with quote

Hate to be professor of the bleedin obvious - are you turning the right way. Its the opposite direction to the other side.

Next step is to strip out the arch liner and see if you can budge it from underneath.

Ian
 
  
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knw911
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PostPosted: Sun Dec 16, 2018 1:52 pm    Post subject: Reply with quote

tried both ways.. (so to speak Very Happy hahaha)
 
  
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deMort
Long Beach


Joined: 21 Mar 2015
Posts: 6675
Location: Brighton


PostPosted: Sun Dec 16, 2018 4:45 pm    Post subject: Reply with quote

Last check before pulling the linner down is have a look in the hole where the adjustor is .. sometimes the bar is at an angle and the tool wont go on it .. ive angled the tool before and pushed to get it on in the past .
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ragpicker
Reims


Joined: 14 Apr 2013
Posts: 4004
Location: North East England


PostPosted: Sun Dec 16, 2018 4:51 pm    Post subject: Reply with quote

These light trays are a great design when they work, but as they get older and brittle they're a nightmare.

The passenger side one in my Boxster has broken where the bar inserts so it can't snap the light into place. Its now held in by zip ties until I get around to putting the replacement tray in. Thats a bit of a pain to do too, hence why I've kept putting it off Rolling Eyes
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knw911
Trainee


Joined: 19 Oct 2016
Posts: 61



PostPosted: Mon Dec 17, 2018 3:41 pm    Post subject: Reply with quote

When a tool (porsche supplied or 5mm socket) is put on the retainer bar, you can feel it spin, but it "spins off".

What I can't figure out is if it ...;

a) the Bar end which the tool connects to has been worn away, effectively taking the edges off the bar meaning the tool spins

Or..

b) the bar is spinning underneath the headlight

And when I say spinning, i dont mean freely. It gets to a point where there is a bit of friction, then it slips, and spins.

Attached are a couple of pics. My fear is A.
 



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911munKy
Montreal


Joined: 26 Nov 2014
Posts: 520



PostPosted: Mon Dec 17, 2018 4:33 pm    Post subject: Reply with quote

If it’s ‘A’ you could clean up the area and using a strong glue (JB Weld) attach an old 5mm socket. That way when the glue has set, usually 24 hrs, you could use an extension bar to turn it.
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asterix_the_gaul
Barcelona


Joined: 20 Dec 2008
Posts: 1263
Location: Cheshire

1999 Porsche 996 Carrera 2

PostPosted: Mon Dec 17, 2018 6:46 pm    Post subject: Reply with quote

It looks perfectly centred so it's not the problem with it not being able to engadge due to off centre hex. I can see the hex looks OK, not rounded, but there's a load of grease over it? It's an odd one as the bar is one piece of metal so don't see how it could break and spin unless the mountings on the headlight are broken somehow?
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deMort
Long Beach


Joined: 21 Mar 2015
Posts: 6675
Location: Brighton


PostPosted: Mon Dec 17, 2018 7:19 pm    Post subject: Reply with quote

Its A .

The tool is a socket so it will fit over a Hex .. you have a circle there im afraid .. there is nothing left to fit the tool over that it will grip to.

However and something ive not noticed before is that there seems to be an allen key fixing in the center of it ..

If it was me i would try a few different allen keys to see if i could release it that way.

At the end of the day though you will need a new base plate .

Trust me .. this is better than B ... as that way you would need a new headlight .
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Paynewright
Monza


Joined: 17 Apr 2018
Posts: 173
Location: Nr Lutterworth Leics


PostPosted: Mon Dec 17, 2018 7:37 pm    Post subject: Reply with quote

What about trying an imperial or BA socket or even a 4.5?

Ian
 
  
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Paynewright
Monza


Joined: 17 Apr 2018
Posts: 173
Location: Nr Lutterworth Leics


PostPosted: Mon Dec 17, 2018 7:40 pm    Post subject: Reply with quote

And perhaps get away with one of these:-

https://www.design911.co.uk/mobile/#part;id=135900
 
  
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knw911
Trainee


Joined: 19 Oct 2016
Posts: 61



PostPosted: Tue Dec 18, 2018 7:53 pm    Post subject: Reply with quote

oh Damn Damn Damn Damn Damn

Well - some questions then folks.

1) If the hex bar has been rounded off, what can I do to get the light out.
2) and once I do get it out, am I right in thinking I can simply replace the hex bar rather than the whole tray?

Thanks guys. For what its worth, I have polished the other light in situ.. and it looks great. Such a difference for little effort. Still want to get them off the car so I can coat them with a UV spray.
 
  
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deMort
Long Beach


Joined: 21 Mar 2015
Posts: 6675
Location: Brighton


PostPosted: Tue Dec 18, 2018 8:19 pm    Post subject: Reply with quote

First of all .. try some allen keys .. im thinking more the bar type .. they have a longer shank .. thats what i would be doing anyways .

Your not going to get any point nosed pliers in that hole i feel so the next step is arch liner and wheel off to get access to the base of the headlight .. i think mole grips on the bar might then work .

From my research looking for pictures .. and experience then im pretty sure you cant change just the rod .. you would need to remove the entire plate reguardless to do this .

I seem to remember the plate is around the £110 mark .. again looking for pictures .. off hand ive never replaced one but i expect the instructions are in the manual .. download in the 996 faq section .
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knw911
Trainee


Joined: 19 Oct 2016
Posts: 61



PostPosted: Tue Dec 18, 2018 8:24 pm    Post subject: Reply with quote

deMort wrote:
First of all .. try some allen keys .. im thinking more the bar type .. they have a longer shank .. thats what i would be doing anyways .


I'm sure this is down to my stupidity .. but how would I use an allen key? The bar is solid. Where would the allen key go?
 
  
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