Write-Up (removing black housing and clear glass lens)
First day I got my 99 clear headlights (from
Car Parts, Truck Parts, Auto Accessories: Just Great Parts Cheap At CarParts.com) and my TRS PnP upgrade kit (
PNP Upgrade: Bi-xenon - Complete Retrofit Kits from The Retrofit Source Inc) with Miromoto 5000K D2S bulbs, FX-R projectors, and E55-R shrouds.
*** Since I purchased another set of headlights, I finished this projector over a course of several days (only working on it for 2-3 hours at a time)
First you have to separate the black housing from the actual headlamp. To do this, you must detach the four anchors holding them together. Of the four, two are white knobs (used for headlight alignment), one is a square anchor/clip, and one is a spring.
First remove the spring by using needle nose pliers to basically grab one end of the spring, pull it up out of its hooked edge and gently place it entirely inside the hole.
Once the spring is removed, use the same needle nose pliers to squeeze the opposing ends of the square clip (yellow circle on picture below) and push it through the opening. This shouldn’t require much force so don’t over do it because you might break the clip.
Now you have removed two of the four things holding the black housing to the headlamp. All that is left to remove now are the two white alignment knobs (green circles in the picture above). There are several ways you can do this but I found the easiest method to be simple removing the bolt that goes through the white knob from the threaded housing. For greater understanding, it might be best to explain how these knobs actually align the headlights. So these white knobs, when turned clockwise, pull the bolt (attached to the actual headlamp) closer to the black housing (thus the headlight comes closer to the housing). One knob adjusts the horizontal alignment and one adjusts the vertical alignment. If the headlight is placed correctly on the floor and you are looking at it from the back, the top left knob adjusts the light vertically and the bottom right adjusts the light horizontally. So the greater the distance between the headlamp and the black housing, the lower and more inward (to the center of the light beam) the light will be alignment. Sooo now we go back on how to get these suckers apart.
Like I said, it’s easiest to just increase the distance between the headlamp and the black housing by turning the white knobs counterclockwise. This increases the gap between the headlamp and the black housing. Then there will come a point where the bolt will basically disconnect from the black housing. As the bolt is near becoming unscrewed from the housing, you will feel greater resistance so be careful. When doing this for the first headlight, I used pliers to turn counterclockwise. However, I later just began using a drill with a 10 bit. Whatever you feel more comfortable with. Note: when turning these knobs counterclockwise, do a little on each knob (going back on forth) so one isn’t super extended while the other isn’t.
Initially the distance between the housing and the headlamp will be this much:
However after you counterclockwise turn the knob, the distance will increase (as shown in the picture below) and the bolt will come undone from the black housing.
Now you should have the bolts separated the black housing will be separate from the actual headlamp. Here is a picture of how the headlamp should look. The green circles are where the white knobs were attached to, the white circle is the spring, and the yellow circle is the clip/anchor where we used needle nose pliers to push it through the housing:
Here is a picture of the black housing (the side which faces the headlamp. The green circles are where the bolts screw, the white circle is where the spring clips to, and the yellow circle is the square hole the clip attaches to:
Now you must remove the electrical connector which attached to the headlight (just pull it off as there are no clips to squeeze) It is the red circled in the picture below. After that connector is removed, take the rubber protective boot off.
Once that stuff is removed, undo the spring clip holding the bulb to the headlamp and remove the bulb. Once I did this, I put the rubber boot, the bulb, and the connector back together just so I have it as a unit. This is what it should look like now:
arty:
