When I was installing my bumper cover and was removing the headlights, I accidentally snapped off the bolt that holds the headlight in place. I was able to get the bumper cover on without removing the passenger side headlight, but now if I ever need to change out the headlight bulb, I think that it is going to be a major pain. Has this happened to anyone here before? Here is a picture of the bolt that I am talking about:

 

This looks like the part of the lock mechanism that you rotate 90 degrees to unlock the headlamp assembly correct? If so did it break off the locking mechanism - I would think that could be replaced. Did it break after you got the headlamp locked into place? Remove the other side and look at the mechanism and you might be able to see what needs to be replaced.

 

Wow you must have forced it real good to break that

 

Did you actually brek it or the headlamp

 

The head of the bolt came out with the socket. The headlight is locked in place. Anyone ever replace the locking mechanism before?

 

I had the same issue on my Touareg, it is a PITA system using a weak cast metal. I think that you have your work cut out for you when you need to get to the light or bumper.

 

Bolt? Sure it wasn't just the sleeve? Use the tool in the tool kit in frunk.

The true part holding the headlight pod in place is not a bolt but a clamping bow w/ a allen key head (which I still see in your picture so you should be fine). Removal tool in your frunk tool kit attaches onto for turning... yes it will reach all the way in there. As you can see, the sheet metal collar in there sort of prevents anything else but it from getting in.

Once the headlight pod is out, it's fairly easy to replace clamping bow by removing the c-clip/locking washer holding it from lateral movement in the tray. Once clip removed, you slide it a bit towards the middle of vehicle releasing outside from tray slot. Then the whole bow slides back out towards front of vehicle.

If your removal tool is stripped, just order a new one or find a really thin walled and long nutdriver (5mm IIRC?) to sneak past the collar and reach the bow. However, if clamping bow is stripped/broken (which is honestly doesn't look like), removal will likely require taking off wheel, wheel well liner and releasing the clamping bow from the back/underside.

Clamping bow is #10 is this image:


Part # needed for new bow is 997.631.273.01 - same on each side.

Here's a link to page from factory parts catalog if you need more help. http://www.autoatlanta.com/porsche-p...-08/905-00.php

Good luck

 

This is exactly the info that I was looking for. The picture above is not of the one that is broken. The bow clamp (item #10 in the diagram) is what broke off all the way to the first elbow. Looks like I will have to go the route of removing the wheel and lining to remove and replace the clamp. I appreciate your help.

 

Wait, don't dismantle your car yet. A lot of times, you can just pull the headlight assembly out of its socket by curling your fingertips (both hands) around the edge of the headlight to get a grip. I've done this a bunch of times without messing with that rotating lock thing (all it does it slide the headlight in and out a centimeter anyway).

 

That sounds like it would be the easiest thing to do, but I would hate to bust the socket as well.

 

The mechanism actually does lock the assembly in addition to pushing it out for easy access. If it didn't lock you'd have headlamps popping out on sudden stops. You can hear and feel it lock when you turn the socket.

 

So is the general consensus that I should be able to just pull on the light hard to pop it out?

 

Nope... not a good idea in general to try it this way b/c you don't want to break any mounting tabs on the headlight pod (or pull the lens off ). Aside from that, you could snap the connector plug ($no idea) or the mounting tray ($110). Search ebay for Porsche xenon lights and see how many will confirm all mounting tabs are located or don't mention (implying it might be hot). Stealing HIDs isn't nearly as common as it once was, thank goodness. Regardless, the halogen pod is ~ $500 to replace... HID will be close to triple.

Now, because in your specific instance the clamping bow is snapped (not exactly sure where) you could try gently wiggling/pulling on it to see if it will release. That said, I wouldn't pull any harder than if were properly released w/ the tool b/c of potential incremental damage/expense.

Personally, it'd take me at most 20 min more to remove wheel and liner to do it right (even getting my wheel mounting guides out, etc.). Suspect the same for you with recent experience installing a bumper skin. Your car and obviously your call but a clamping bow is < $7.

Good luck

 

Oh, no kidding, better not then, could be expensive. Probably not worth the risk if you can easily remove your wheel and rear panel. To be fair, I've actually done this on two different 997's without a problem, and it really doesn't take that much force (which was surprising). You're pulling straight out, not angled. That rotating bar thing is essentially doing the same thing - pushing the headlight assembly forward along a track about a centimeter before it slides out freely. But probably beter safe than sorry.

 

I appreciate the feedback. I'm going to do it the hard way and remove wheel, liner, etc.