Repair
Stage 2 - Repair
Now the damage can be assessed...
Usually the top connection between the adjuster mechanism/shaft and the chrome reflector panel breaks. You will see a small white lug, which will have broken away from the reflector (see photo 5). These lugs are designed to push through the reflector panel and twist 45 degrees to lock into position - but they brake alot!!
Photo 5
It is likely that the end of the adjuster may have disconnected from a small ball joint as you work. If so, insert the white lug (see photo 6) into the reflector panel, twist 45 Degrees (long nose pliers) and use it to push the lug onto the small ball joint. You should hear a click as it goes back on
.Photo 6
It may be that more than one of these lugs has broken - if so treat them all the same and repair as follows.
Next step is to re-enforce the connection using a short self-tapping screw with washer (see photo 7) - I used a small screw with a 6mm long shaft and roughly 3mm wide, size is important as too larger screw may split the white lug.
Photo 7
Once this step is complete - test fit the unit back on the car (before fitting lens). To check the correct adjustment of the headlight can be achieved, park the car facing a wall, garage door or flat surface - I used the rear bumper of another car. Use the adjuster to move the chrome reflector into the correct position.
This is only a rough test, which will hopefully allow the MOT man to use the fine adjusters to sort things out - If your worried, take an 8mm spanner along and oblige. Remember - the passenger side (UK) should be slightly higher than the drivers side headlight. If you have one good headlight, which is correctly adjusted this should be easy.
At this point you will know if the unit is good enough to re-use. If not, it only took 20mins
. If it’s looking good, continue with reassembly !*The headlights should always be checked at an MOT centre using the correct equipment. It is difficult for the MOT man as if he (/she :slayer
breaks your headlight they get the blame - so go easy... Although the repaired unit should be as strong as before.Now for Re-assembly…
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