Replace H4 headlight lens

[chauser]

Driving home this weekend I stop and the stop sign 2 blocks from home and hear 'pink, crackle crackle'. Get out of car and the headlight assembly lay on the road - somehow, the screw holding it in at the base must have backed out as it was no where to be found?

I have a replacement lens ordered - but looking at the headlight assembly it looks like you have to disassemble the entire unit to replace the lens?

Is there an easy way to do this?

Thanks

[chrisbruck]

There are some funky metal spring clips that hold the glass in place against the housing. Take them off one at a time and pay attention to the orientation. Not rocket science but mine were aggravating and took a few tries to get them all back on spaced correctly.

[wwest]

Take GOOD pictures of the way and type of clips used first.

[redturbo911]

You might want toreplace the seal to save yourself from any moisture in the future. Ask me how I know? Lol.

[jorian]

Saw this happen at a local autocross a few years back. Bummer. When you replace the lens it's a good time to attach a lanyard/zip tie from the lens to the inside bucket to prevent, well you know...

Do both sides while yor in there. The little screw is totally inadequate to hold that assembly in place.

[RSBob]

Before you reinstall the whole assembly, use a large zip tie secured to the H4 assembly and the what ever you can find in the headlight bucket - even the wire loom. If it comes loose, it won't hit the ground.

[Canada Kev]

Originally Posted by RSBob

Before you reinstall the whole assembly, use a large zip tie secured to the H4 assembly and the what ever you can find in the headlight bucket - even the wire loom. If it comes loose, it won't hit the ground.

+1

And some safety glasses are probably a good idea as those clips can spring out and fly across the room. Or into your eye.

[Jesse16]

++1 on safety glasses. Don't discount the possibility of flying springs. I had one go 20' across my garage and under a cabinet, PIA to find. Very old school headlight retention but they do work.

[uwanna]

Originally Posted by wwest

Take GOOD pictures of the way and type of clips used first.

Better yet, remove your other headlight, place side by side, and use it as a guide on spring clip replacement. Makes it real simple.

[wwest]

While you're in there projector Hi/lo HIDs are readily available on Ebay.

[redturbo911]

Tell us more about this please.

Originally Posted by wwest

While you're in there projector Hi/lo HIDs are readily available on Ebay.

[chauser]

Thanks for replies.

Is it necessary to unscrew all of the adjuster screws in order to pull the reflector off and slip new lens in, or is there an easier way?

thanks

[manbridge 74]

I generally pull the rubber grommets off with screws and lift lens off. You can make new rubber pieces out of vacuum line if needed.

Also the factory retaining method is not THAT bad as long as all hardware/seals are in good condition and metal tabs and H4 rings are properly formed. Some additional retaining is a good precaution as these are 40+ years old. I also like to try and pull them off by hand when done mounting. If they shift at all or lift off the top tab some more adjustment is required.

[Soterik]

FYI, that's an H1 assembly, not an H4, so if that's your light assembly you need an H1 glass. Same dynamic in your work.

Previous post to mine indicates that you pull the adjuster metal "arrow" out of the rubber grommet, or remove the grommet entirely and then replace as he indicated.

Individual springs are available from the VW guys for cheap vs a Porsche supplier.

Have fun!

[chauser]

Thanks for method for replacing lens, and for pointing out it is an H1 not h4 headlight - time to order a lens.

Charles

[jaudette3]

I restore H1's and they can be a little tricky. The screw that's attached to the spring coil will probably be impossible to remove. But you can just leave it attached to replace a lens. Pull the prongs on the two adjustment screws that have them out of the small rubber tubes on the large reflector. Then back off the other adjustment screw that screws into the high beam adjuster. Remove the spring clips and you can then wriggle the housing away from the lens and chrome trim ring. PM me if you have any problems and I'll try to help.

[chauser]

Thanks John

I hope to tackle it this weekend, and will ping you if I get stuck.

Charles