Gotta love McMaster


Thanks for the link...

Thanks for the pictures, and the info. I'll give it another try.

Here is the part number for a replacement screw if yours is to rusty to reuse 911 631 033 00.

Howard gave the answer. That slotted screw holds the headlight and the small screw holds a painted ring when you use that type of ring. Usually it is painted the car color some people like that look instead of the chrome rings. Definitely those are H1s.
Yes, those screws belong there. Most probably the retaining nut stripped (actually it is a piece of steel strip with some threads). Follow SoCalSK8r instructions and you should free that screw.

Hope these pictures clarify how these screws work to hold the trim ring.

Slotted screw and screw for trim ring

http://forums.pelicanparts.com/uploa...1361593803.jpg

H1 without the trim ring

http://forums.pelicanparts.com/uploa...1361593893.jpg

Trim Ring

http://forums.pelicanparts.com/uploa...1361593946.jpg

Trim Ring and H1

http://forums.pelicanparts.com/uploa...1361593991.jpg

Trim Ring and H1 half way in

http://forums.pelicanparts.com/uploa...1361594046.jpg

Trim Ring and H1 all the way in

http://forums.pelicanparts.com/uploa...1361594097.jpg

Success!! Thanks for all you help.

Now one other question. Can the aiming mechanisms be repaired? The drivers side lamp has a very conspicuous looking linkage.

It can be done but it will be difficult. The major problem is to find the long screws.
These pictures show how the aiming mechanism should look.

http://forums.pelicanparts.com/uploa...1361595857.jpg
http://forums.pelicanparts.com/uploa...1361595873.jpg
http://forums.pelicanparts.com/uploa...1361595890.jpg

The issue it looks like I have is with the flexible drive shaft and it's connection with the adjusting screw that is on the outside of the lamps. It looks like it was broken at one point and badly repaired. Also the threads are shot near the head of the screw, so the flat square nut is not holding the head of the screw still which is causing alignment problems inside.

I was able to source a 70mm m5 screw.

Are the flex shafts available? Seems like a long shot. I may be able to weld the two together.

Any advice?

Check here.
I think the problem is solved.
McMaster-Carr

Edit - donporfi types faster than I do...

Thanks guys. I have one on order. I ordered the Stainless due to the 2 bend radius. the steel is 4" which I think will be too tough. It's 6" long which will mean I'll need a shorter screw etc.

We'll see Tuesday morning.

Next question is, can I remove the flex shaft from the other screw? Looks possible, but fragile.