I'm having problems installing H4's

RickKlem · 07-03-2004, 04:37 PM

I have been trying to install my new H4's and I'm having problems. Sorry so long ,But......

First of all, the rubber gasket (large O-ring) that fits on the outer lip of the fender does not want to stay on and when it does, it is in the way of the trim ring of the light. This gasket has a flat side and a ridge or lip on the other side. Which side goes toward the fender and which side faces the light ring?

Secondly, the new H4 light ring does not want to stay attached at the top. As soon as I start to tighten the only screw that holds this assy in the fender, the top starts to pull away from the fender. I know that the lip behind the ring should slide over the top lip of the fender, but the ridge on the light ring is VERY small and it does not have enough .....grip or clamp leverage . Once you add in the thickness of the rubber gasket ,now there is no room for the ring lip to grab the fender lip.

Also my old light assy had four screws that held it into place so the bottom left tab was in the way of one of the adjusting screws for the new unit. I had to bend that tab over to get it out of the way. I have never read any threads where people had to do this, or of any problems like I'm experenceing.

I spent the last three hours trying to mount ONE light. What the hell am I doing wrong.

Help Rick

geof33 · 07-03-2004, 04:59 PM

Rick,

The rubber goes on with the flange (not flat) side out. Lube them up with a good rubber conditioner and clean them well. When you put the new light on you need to push the light back and down at the top until it sort of "clicks" and is obviously in place. Then make sure you wd-40 the set screw and the welded nut. The angle is pretty steep for the new set screw, I bent back my lower tab a TINY bit to help line them up.

Also, make sure they are on perfectly straight or they won't lock down.

Good Luck...

kumma · 07-03-2004, 05:23 PM

i know what your going thru, i was only able to intall the drivers side light and it fit very poorly, on top of that both gaskets i bought from pelican snaped in half as i put them over the fender.
the light did fit without the gasket though.

there just sitting in the box until i get motivated again.

to quote from buckaroo banzi "its a very baddddd design."

Kraftwerk · 07-03-2004, 05:45 PM

I had problems too getting the new H4's to fit on the old bucket. They seemed just
a wee bit too small.... It finally settled but it was a force-fit and I think I may have stripped one of the screws. The gasket may be a tiny bit large for the application or worse the ring might actually be a bit too small for the bucket. Who knows? It wasn't easy fo me either.

RANDY P · RANDY P's Garage

It's a hassle. Same story here, I finally wound up bending the upper retaining tab outward a bit - not much but a bit and pulling and re arranging the "wires" inside the bezel so everything cleared. Yep, bent in the lower tab a bit too. Angle was off on mine.

Definitely protect that nut at the bottom that the screw fits through. paint it if its bara and might even try a dab of anti - sieze. Mine was rusted all the way out and had to drive the car without a headlight to a shop to have it ground out and rewelded with a new nut. Not fun.

It'll go, but you'll bend it. It also requires a longer screw than the USA headlights used. If you plan on using painted trim rings, it's a two piece screw that's required. One goes through the housing and into the lower tab, and then the painted outer ring shaps on, and another screw that threads into the larger, 1st screw secures that. I was told during my quest for H4's that the USA 1 piece screw "would" work. Forget that, I went with the factory solution.

rjp

turbo6bar · 07-03-2004, 06:23 PM

I curse the engineers of the H4s. I'm glad I'm not the only one who's been pissed at these headlights. I even bought brand new H4s, but I'm still having trouble. Funny thing is I can install the left headlight easily, but I cannot get the right headlight to fit at all. However, I did use the old gasket on the left side. I bet that is part of the magic.
I'm embarassed to admit the right headlight is held in place with racing tape. It haven't stored enough patience to tackle it again.
Jurgen

geof33 · 07-03-2004, 07:04 PM

Wow, you guys are having some trouble!!! Check the rings on the fender. They go on counter intuitive. Mine snapped right on, but I did have to finagle the screw (mine were new and the longer one was supplied) but you can easily cross thread the tab. It's a really funky angle, and you can't bend it too much or you can't get the screw to line up at all. I wonder if there are subtle differences in the later year buckets... Mine is an 84...

techweenie · techweenie's Garage

I've employed three different techniques to solve the problem:

1. The main screw tab at the bottom needs to be rotated toward the front of the car (straighter/flatter) a bit so that tightening the screw pulls the upper ring into it's seating lip instead of pushing it out. There's very little movement here, though.

2. When the bucket itself is mis-shaped, a 'collar' spacer on the bottom screw will keep the ring from being pulled too far in at the bottom.

3. When all else fails, some pressure on the upper part of the ring, flattening the upper curve a bit, will keep it from popping free.

It can be tedious... a beer or two can be helpful.

nullh2o · nullh2o's Garage

When I replaced the US spec H4s on my SC with the Euro H4s I was somewhat shocked by the cheesy build quality & questionable design of the Euro version. At least it *looks* alot better.

Zeke · 07-03-2004, 09:25 PM

No problems here. I did the H4 easily in a day and a half.

RickKlem · 07-04-2004, 07:06 AM

Thanks everyone for the input.

This is day two of the project and I'm headed out to the garage and give it another try. Right now I would rather be having my teeth pulled. Removing the engine\tranny was not this hard!!!

Here goes
Rick

svandamme · svandamme's Garage

mine didn't have any rubber when i stripped my car
the left side went on it , no problem
the rightside isn't tight

didn't even know there were rubber rings to put in there
they're on my project list now

Kraftwerk · 07-05-2004, 10:28 AM

Stijin,
What happens in the rain / do they fill with water?

It was the biggest pain to retro-fit these damn things on there.
Every other repair i have done has been a breeze....

RickKlem · 04:03 AM

THERE INSTALLED,

I removed the ring from the light housing. The lip that is underneath the ring was rolled two tight or flat for my fender lip to grab. I placed a small screwdriver under the lip on the ring and bent the lip outward a bit. This gave it more of a gripping area. I then test fitted just the ring onto the car. This way you can see any alignement issues, and you can make the needed adjustments. I had to tweek the mounting bolt that is welded at the bottom of the bucket. I also had to bend and shape the ring to match the bucket. Once I had the ring fitting the bucket correctly , I placed a piece of masking tape across the fender and ring ,made a few marks or lines , cut the tape at the joint. I used these marks later to help line it back up when I installed it for the final time. I put the light housing back together, making sure not to deform the ring. I placed the top of the housing on the car while lifting up and back on the bottom of the housing , then pushing downward on the top of the housing and holding pressure on it while placing the screw in the bottom. It installed with no problem.

I'm glad thats over
Rick

david914 · 07-08-2004, 06:57 AM

Congrats!

Now you can enjoy "real" lighting!

JonT · 07-08-2004, 07:08 AM

I had the same problems with my H1's I recently put on. One side was easy to install and fits beautifully and the other was difficult to get to "grab" the lip and still has a gap so not much moisture protection here. I just don't spray it directly when I wash. Congrats on completing your project. Wish I would have posted like you did requesting for help.

K-Jetronic · 07-09-2004, 01:22 AM

So congrats to all, my PO did exactly the same upgrade. But now I need to replace a bulb and cannot get the assembly out. I took off the trim ring, removed the bottom screw...but are unable to remove the unit. It will twist a little to the left and right but no forward movement AT ALL. Rubber ring is installed. Any suggestions from you H4 installation experts.

Gerko
1978sc