H4 upgrade 911sc question

[911trackcar]

I’ve installed the H4 headlights on my ‘83 SC. With lots of work I’ve got ‘em on with new seals. Took a helper adding downward pressure from top of headlights to get them to catch and get bottom screw in place.

Here’s my question. Both screws did catch. And a few hours later I’m out double checking the work. The headlights are in place and not moving at all. But strangely one of the bottom screws is pretty loose. It’s won’t tighten anymore...and when I try to loosen nothing happens. Screw can be pulled in and out. But I can’t take the headlight off at all! It is firmly attached, not moving.

Any ideas on how to get it off again? Or (dumb question), will that headlight not pop off while driving now? Even though that bottom screw is not firmly in place..

Thanks for the help!


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[Canada Kev]

Is the bottom screw turning freely? It just screws into a threaded tab in the bucket that commonly strips out, thus not offering any mechanical attachment for the headlight. The rubber seal may have sucked itself tightly to the light and that's why it doesn't want to release. However, I wouldn't drive like that as some shifting or bumping of the car on the road might release it and then your pricy light might come loose.

If the screw is stripped, you can weld a nut to the back side of that tab so the screw will turn into that. Or you an do what I did on mine when this happened and get a "nutsert" in the screw hole, a blind fastening threaded nut that crimps in place. It's a bit of a PITA, but once done, it's pretty much a forever fix.

[911trackcar]

Ya turning freely. You’re right I need a nut on the back side of the tab. In fact there was a clip there prior.. thought the new screw was thicker and would catch.
Definitely don’t have the welding skills nor tools that option is out.

I can look into ‘nutsert’.

Wondering if gluing a clip or nut-type would work?


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[Jack Stands]

The rivet nuts are available at McMaster-Carr (though in packs of 25), and you have to be sure of the thread size. However, that might be an excellent repair option if you can’t get a nut welded onto the tab. You will need the installation tool as well if you don’t have one.

[uwanna]

Originally Posted by 911trackcar

Ya turning freely. You’re right I need a nut on the back side of the tab. In fact there was a clip there prior.. thought the new screw was thicker and would catch.
Definitely don’t have the welding skills nor tools that option is out.

I can look into ‘nutsert’.

Wondering if gluing a clip or nut-type would work?


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I had the same stripped threads problem as you have. I went to Ace
hardware and found a nut with the right thread and epoxied it to the
back of the threaded tab. Worked just great! Just be sure not to
get epoxy into the thread hole, or if you do you can use a thread tap to clear it out. Good luck!

[RSBob]

Mine was stripped out and inserted a small white plastic sheet rock sleeve into it. The sleeve expands in back of the nut and locks into place. I then successfully was able to screw/anchor into that for 5 years, until the car was sold.

I also secured long black zip ties on the back of the headlight to the wire loom in the bucket as security in the event the headlight ever tried to eject. Used them on my current car too as insurance too.

[911trackcar]

Thanks for the ideas, all! Will give it a shot tomorrow.


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[911trackcar]

So the other big issue though is I cannot, for life of me, remove the headlight. Honestly it feels glued on! I’ve tried different methods and I’m tapped..


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[tirwin]

I had a similar problem the first time I took my H4's off. I used a small flat blade screwdriver to get behind the head of the screw and apply a little leverage while I used a phillips with my right hand to back it out.

It is really easy to cross-thread that nut and the screw actually angles upwards slightly. I think someone tried to screw it in straight on and cross-threaded it. I was able to save the nut by re-tapping it and being very careful when I put it back together.

[gomezoneill]

I would use something plastic like a upholstery tool or a plastic knife to pry with.

[famoroso]

Consider using a dental pick with a 90 degree tip (or something similar). Insert pick into empty screw hole, "hook" the rear of the trim ring and pull forward. It may pop off rather abruptly, so plan accordingly to protect the surrounding body / paint.

[donporfi]

Instead of the threaded part you can use a clip on nut.
McMaster sells those.

[911trackcar]

Thanks for all the help. Love this forum and the users. Ended up popping off the H4 with a plastic molding/trim remover.
Then JB Weld’d a nut. Wasn’t the prettiest. But it worked!


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[911trackcar]

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[runner4fun]

I am about to install Euro H4 headlights in my 1983 SC. Other than the screw at the bottom center of the headlight (the topic of discussion above) and the sugar scoop, where does the headlight attach at the top??? Thanks

[911trackcar]

Originally Posted by runner4fun

I am about to install Euro H4 headlights in my 1983 SC. Other than the screw at the bottom center of the headlight (the topic of discussion above) and the sugar scoop, where does the headlight attach at the top??? Thanks

There is a slight edge at the top of the fender that the top of the H4 assembly will 'clip' into when tightened.

Good instructions:

https://www.pelicanparts.com/techarticles/101_Projects_Porsche_911/71-H4_Headlamp_Upgrade/71-H4_Headlamp_Upgrade.htm



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