Rennline LED Headlight Install - Help!!!!

[dkirk]

Purchased the Rennline LED Headlight Upgrade Kit from our host for installation in my 1988 Carrera. I selected the primed headlight trim rings and had these professionally painted by a local shop. Have a little over $1200.00 in this project thus far. What was stated as a 10 minute per side installation has turned into a 5 hour ordeal from hell. I have installed other Rennline equipment on my 911 and parts have always fit perfectly...not so with this one. I'm hoping other members of the forum who have had success with this kit, could offer some advice.

I read the instructions through several times before starting the project. They are a bit vague in some areas - additional pictures and/or diagrams would be suggested. The headlight lens gaskets are problematic. Once stretched over the rim of the lens and positioned according to the picture, they tend to pop off during the fitting of the lens into the headlight assembly. There is a molded channel in the gasket which logically would seem to fit over the rim of the lens, but instructions state (and poorly show) this channel to be facing outward. The design of this gasket could be greatly improved upon. Below is a picture of the lens with gasket fitted into the headlight assembly. Does anything look wrong?



Last, and most frustrating of all, is the headlight ring. It partially fits over the plastic headlight assembly, but there is nothing anchoring it at the top. Once the one (and only) lower attachment screw is affixed to the ring, there's nothing that holds the top of the ring in place - one can easily push it forward with one finger. The ring will not fit over the plastic headlight assembly entirely as ring is too small. Other than gunning a hole in the top of the ring and fitting a screw here, what holds the ring in place at the top?



I called Rennline tech support earlier today and left a help request but they never called back. Not very pleased with their product or product support. Can someone on the forum please offer some advice? Thanks in advance.

[Canada Kev]

I don't have the Rennline lights, but on regular H4s, that painted trim ring should have a small lip at the top that kind of hooks over the headlight ring around the lens. You might need some slight pressure to "snap" the top of the trim ring onto the headlight assembly. When the trim ring is hooked onto the light, the single hole at the bottom should fall into place and line up with the headlight mounting screw at the bottom. The ring mounting screw threads into the head of the headlight assembly mounting screw.

Looking at your pics again, maybe the hooky lip of the trim ring is supposed to snap into the horizontal slot on the light?

I hope that helps a bit. Good luck!

[Otter74]

I haven't done this myself, but I bet Kevin is right - try removing the screw at the bottom of the ring, and then make sure to hook the (presumed) lip on the inside of the top of the ring into that slot, make sure it's engaged, and then seat the screw.

[ELUSIVE]

Perhaps this video could provide some assistance.
I'm currently awaiting my Rennline LED lights, so i've been researching how to install.

https://www.youtube.com/watch?v=YLPJGnMSRd0&feature=emb_title

[slow&rusty]

I was thinking about this Rennline kit for my own car, so will be reading with great interest.

[dkirk]

Thank you to all that have responded and offered suggestions and help. Below is a picture of the back side of the Rennline trim ring, at the upper surface. The edge has no rolled lip nor tab to engage with the slot in the headlight assembly. I realize this picture is poor, but just wanted to show that there is no provision for attachment in this location.

I watched the video but a good shot of how the headlight ring attaches at the top was not evident (unfortunately).

[dkirk]

The other issue is dealing with the lens gasket. This is a flat molded rubber ring that has to be stretched over the flange of the lens. Instructions state that "Be sure the ribs of the gasket face away from the lens" and this is shown in a picture in the instructions. I have it installed as stated (shown in my picture), but this just doesn't seem right - the gasket flys off the flange at the slightest disturbance during installation. Logic would be to install with the ribs inward and the channel of the gasket against the lens flange but I'm trying to follow the instructions. Bottom line - this should have been a dedicated molded part that fits the lens flange perfectly.

Those of you interested in this headlight kit - watch the classifieds. I may be selling the whole thing including the red trim rings for half price.

[Canada Kev]

I can't speak much for the gasket - the H4 lights are also fiddly.The ribs being out may be just to minimize chances of water ingress.

What holds the lens to the assembly? Does the whole thing install in one piece or does each component stack into the headlight bucket one piece at a time - reflector/bulb assy then lens then black retaining ring? For reference, the H4 stacks together in multiple pieces, but it goes onto the fender in one homogenous assembly that wouldn't fall apart if you set it on the counter.

It's also difficult to see from your photos, but does your painted trim ring outside edge roll in just a bit? In the pics, it kinda looks like it, but could also be shadows.


I'm referring to some shadows and highlights like the long narrow reflection at the top position of the ring (middle of pic) and shading on the lower right of your pic.




And the shadow at the upper right by the tape mark...




If it does have a roll inward, even a very small one, that's likely what will hold the trim ring on.

On Euro H4s, the light assembly attaches to the fender by the catch at the top of the bucket and then the one screw at the bottom holds it there. Then the painted trim ring slides over that and then uses a second screw that threads into the head of first screw to hold the ring in place.

I see in your photos that you have the black ring already mounted to your fender with the painted trim ring not there. On yours, is it just a single screw at the bottom that fixes the whole collection of parts to the fender, including the trim ring? If that's the case, and there is indeed a small roll at the outside edge of the painted ring, it may have to be already over top of the black retaining ring before you try to clip it (black ring) onto the fender by the lip at the top of the headlight bucket. Then the single screw at the bottom would capture the trim ring and all the headlight pieces.

I hope I'm making sense here...

[dkirk]

Kevin - thanks very much for your helpful questions and suggestions. Here are some answers:

The lens is trapped in the assembly by the lens gasket. The fit is snug and the gasket moves on the lens when installing, sometimes flipping off entirely. I learned that soapy water helps. Here is a picture of the lens installed with the gasket positioned uniformly.



Installation is one piece at a time. You cannot do a sub-assembly, then install into the bucket.

Trim ring has no rolled edge anywhere. It appears to have a rolled edge from my photo, but is totally straight-edged all the way around.

The Rennline light assembly attaches the same way as the Euro H4's, bucket clip at 12 o-clock and single screw at the 6 o-clock position.

The black plastic ring that you see in my photo above is actually the headlight frame assembly fully seated and installed in the bucket. The single screw at the 6 o-clock position plus the bucket clip is what holds everything together. The instructions state to "start at the top of the trim ring and push the trim ring down over the headlight frame until the screw hole at the bottom lines up with the headlight bucket threads". This is impossible to do - trying this just allows the ring to pop out at the top as there's no means of retention. The ring when held in place allows some of the black headlight frame to show uniformly-this looks fine. Drilling the ring at the top and putting in a screw would easily solve the problem but I shouldn't have to do this, plus I like the look of a clean headlight ring.

[84NEUN11]

I experienced the exact same issues that you did. I was convinced I was doing something wrong. Had to walk away for a couple days before I broke something. Went back at it again and could not get the trim rings to attach properly.
I even tried to assemble everything on the bench to make sure the problem was not my fenders being out of wack. trim rings still would not fit properly. I also noticed that one of the projectors was not firmly attached to the housing allowing it to rotate. At this point I called Pelican to request a return. They requested an explanation of the issues which they forwarded to Rennline. Needless to say the lights are now on their way back to Pelican.
I have a placed an order with Audette and am awaiting delivery. Very disappointed with the overall quality of the kit from Rennline.

[gremlin]

So i have the rennline lights with the chromed trim rings and had none of these issues. the rubber didn't come off of my lens until one of the lights popped out of the car and it shattered. This was not Rennline's fault, it was mine, I didn't realise a previous owner had gone from M5 to M6 screws in the headlight buckets and that those were also now stripped. I now have M5 Riv-nuts pressed into the tabs and my biggest issue was needing another person to get the gasket around the body, rennline helpfully provided me a diagram of how that fit which made it easier, then I installed the bucket and aimed the lights, removed the screw and put the reflector lens and cover in. I did give it a solid whack at the top with my palm several times to make sure the chrome trim caught over the top of the light but once it had it's was hard to get off from the dry fit.

I think there's enough variance in the way the cars are built that there will always be some issue, my understanding is the Audette lights attach in the same manner, from the video shown above.

I'd recommend getting a second set of eyes on it if you can, put on a mask take it outside, maybe stop by your mechanic and have them take a look see in the parking lot

[84NEUN11]

100% agree about the variances from vehicle to vehicle, hence why I tried to assemble on the bench. Even with out the lenses in place the trim rings would not fit over the headlight housings. I had the black trim rings, OP had the prime red trim rings. Maybe the chrome trim rings fit bu there was no way the black trim rings I had were fitting over the housings.

[slow&rusty]

Extremely disappointed to hear of Rennline's poor customer service.

[gremlin]

Did you contact Rennline directly? I found their customer service for the lights and several other things I bought to be exemplary, really amazing in fact. Right after installing my lights when that one popped out it shattered the glass. I sent them a note asking which part to purchase to replace it (it was my fault that I didn't notice the hole was stripped) and they sent me a new lens which they absolutely didn't have to do.

They also answered every question I had quickly and efficiently.

Not affiliated but just a happy customer

[dkirk]

I certainly thank all of you that have responded - feedback and suggestions are greatly appreciated. I did call them last Friday and requested technical assistance but did not receive a call-back. On Saturday I contacted them via e-mail and stated the issues and provided a link to this forum thread. Hopefully, they will return my call or e-mail this coming Monday. I will keep everyone informed of how this turns out.

[84NEUN11]

Pelican approved the return of my parts.
I assume that Rennline accepted my explanation of issues and approved the return.

[dkirk]

Got an e-mail response from Rennline today and they are working with me to resolve the problem. Will keep everyone here posted on the outcome.

[MichaelSJackson]

I used to have this same problem with the trim rings on my H1s.

Trick I learned was to attach the ring with the base screw just started; very loose. Then push/press the top of the ring over the top of the bezel. (Looks like yours is a black rubber piece?) Then while holding it in place at the top, tighten the screw at the base. The trim ring has the same rounded shape I see in your photo and should hook on this bulge (not a little indent) as the screw pulls the ring downward.

First couple of times I did this, I'd have to "mold" (press, push, whatever) the ring to the correct oval to match the headlight. Anymore it retains the correct shape and it simply goes on. I hope your solution is this simple.

I've wanted to purchase Singer headlights ever since I first saw them. So I'm pulling for the Rennline solution.

[dkirk]

Michael - thanks for the suggestion. I tried your method too but no go - the headlight rings just will not fit properly over the black plastic headlight housings. I even tried fittment with the lens and gasket totally out of the housing. I've tried hand-reforming the ring to better fit the housing contours without success. The picture shows the ring attached at the top with my thumb pressing like hell on the bottom - no way the hole lines up.



Rennline sent 2 new headlight lenses with slightly smaller rim dimensions (no charge). This made gasket installation and fittment into the headlight housings somewhat easier. But the Headlight rings still do not fit. Next step is to request new headlight rings which I'll have to have painted again. I've reinstalled the factory original headlights so I can at least drive my car during the nice spring weather we've been having.

[tmaull]

I believe Rennline is rebranding some else’s LED kit. They’ve started doing that with a number of parts. That said, I’ve found RL to be good products with garbage instructions in the past so who knows. Sort of surprised they aren’t falling over themselves to support their product on this public forum tho.