H4's keep popping off. What can I do? - RESOLVED-Thx
 

PROBLEM SOLVED - Kill this thread - Thanks.

I just bought H4s to upgrade my 82 922sc and when I go to tighten them with the bottom screw, they pop off. Is there a fix for this or am i doing something wrong?

On a 75 there is a small lip that you need to hook the trim ring behind. It is at the top of the headlight hole perimeter, on the fender. If you are using new gaskets it takes a little force to get it to seat.

Lower the trim ring onto the lip and keep downward force on the ring as you push the trim flush.
Then insert and tighten the screw.
You'll get it.

I've tried that. It seems that as a result of tightening the screw at the bottom it pulls the light in and up form the bottom and then the top moves up as well causing it to pop off.

Almost sounds like you are over-tightening the bottom bolt. It just needs to be snug enough to compress the rubber gasket and hold it in place.

Had the same frustrating problem on one of mine when i switched to H4's.

Not suggesting this is the right way but i went with a BFH. made some adjustments to the bottom tab.

Was not fun at all and i was lucky not to crack any paint.

I am defintely not over tightening it. I am looking for answers from people who have had this issue and corrected it.

+1, screw acts more like a "set screw" rather than a "screw down tight" screw.
That combined with new gaskets make it a little frustrating though.

Yep, a little tab persuasion may be necessary.

Well, I've had the issue, so do I get to play?

Do you have the rubber ring-to-fender gasket installed the right direction? Is there a paint build up inside the bucket to fender groove?

You know, if you supply us with more info and maybe a pic or 2, we might be able to get this resolved.

FWIW, a lot of guys run a tie wrap safety inside the bucket in case it does pop out. It's not an uncommon problem, but with some specific tweakage, the rate of occurrence can be improved, maybe totally corrected.

If I remember correctly there is a wire criss cross spring assembly that holds the light to the trim.
Perhaps the assembly is getting in the way of the trim ring seating properly behind the lip.
I think I had to deal with that.
Check that out.

It's difficult when using thick new gaskets made for the H5 headlights...

Try bending the top inner rolled edge of the ring lip down a little so there's more of it hooking onto the tab on the top of the fender/headlight bucket. They are made of brass and be very careful not to chip, lift, or wrinkle the paint or you'll have to repaint the rings afterward.

Also make sure the screw on the bottom is not cross threaded so the screw is going in at a higher angle then it should.
It should be angled down quite a bit, so much so that a foot and a half long screwdriver is easier to use on it because the handle will be out in front of the bumper as your using it providing more room for your hand on the handle.

If that doesn't do it try bending the tab that screw goes into forward a little so the screw angles down more which will help hold the ring lower in the bucket so it hooks on the tab better.
And, push down and back on the headlight ring while tightening the screw so it is hooked onto the tab on top as good as possible and compressing the gasket a little.
Going over bumps will pop them off if the top of the ring isn't hooked behind the tab on top... it's a very weak design, and someone could quickly steal your headlights by removing that one bottom screw.

It's unfortunate they aren't made as solid with a cast aluminum frame and held on with the 4 mounting screws behind a trim ring the same way as the crappy light output 1987 on, made for USA, DOT H5 headlights

If he acts like such a piss-ant over this imagine when something serious goes bad!
SmileWavy

it is a frustrating thing to work on. probably just walked in the house cussing away (as i did when i did this) and hopped online to find some help.

I had the same thing happening with my 73. I ended up having to bend out both the H4 lip and the lip on the fender. Oh and ditched the new gaskets and put the old ones back in.

Now they are good but it was a mess and I thought I was going crazy for awhile. Even put my sugar scoops back on to test fit and trhey fit perfect.

The new H4's are not built as good as the old ones.....even if they are original Bosch and I paid $400 for them from our Host......Just part of having an old Porsche

It's not rocket science and there is no reason to get enraged over it. There is a tab on the bucket that has to hook to the tab on the headlight ring!! If it's not staying hooked one of the two things need to be adjusted. Or maybe he doesn't have the rubber O-Ring installed correctly. Maybe try starting the screw in a couple turns and then try snapping the ring into place. Sometimes it takes a good whack with the heel of your hand to snap it on...

Thanks Milt, wowzer, beretta fan, jfairman and dipso. I am going to try some of your suggestions. This is exactly why I asked the question here in this forum...Solutions!

GaryR, if you have some knowledge to share on this topic, which I doubt, then share it, otherwise shut you pie hole and don't crap on my thread.

Uh oh, looks like this is going to OT.

Wondered how long before this guy went down the direct insult road.... good luck pal, you're going to need it.

GaryR, I believe you threw out the first direct insult when you called me a "Piss-ant". If you just left out the comments and offered your suggestions first rather than later this wouldn't have happened. Think before you speak (or type in this case). All's good with me. :)

This is how I fixed mine. The trim ring just wouldn't stay hooked until I whacked it down a couple times. After that, I can barely get them to come off even when I want them to.