964 Tail lamp lens replacement
 

I need to replace the right tail lens on my 1991 Carrera 2. I already have a replacement lens but need to replace the discolored one without destroying the rest of the assembly. It appears to be quite securely bonded. Is there a safe way to remove the old lens?

You will have to replace the whole unit.

964 tail lamp lens replacement
 

I got this lens elsewhere but Pelican does sell them as just the lens without the assembly. They say that instructions come with them but I didn't get any. I could try the Dremel but was hoping there was a trick or simpler/safer method such as a heat gun or...

Dansk do a lens only kit that also includes the plastic adhesive/glue. Have done this with a friend's tail light - works a treat, very effective.

Parting the old lens from the unit is a case of putting the whole thing in the oven at low temp for a short while and the lens is then easy to gently pull away. All in the Dansk instructions.

A bunch of people on Rennlist have done this, but it requires patience.
The assembly is heated to 100 deg C for 20 minutes. The lens is then parted from the housing with a sharp utility knife or hobby knife. The new lens is then glued on to the housing. Some people then seal the perimeter with silicone sealant.

https://rennlist.com/forums/964-forum/898115-design-911-rear-indicator-lens-replacement-tips.html

Our host sells both lenses and glue.

That's the one. Worked very well if done carefully and taking your time. Many car washes since and still good. Only precaution we're taking now (for peace of mind) is just run a strip of masking tape across the lens top if snow-foaming/karchering..

I am finally ready to do the replacement procedure by heating the unit in an oven to 100C.
Question: do you try to separate the old lens while the unit is still hot or can you let it cool?

IIRC I believe we very carefully parted the contact surfaces pretty much when it came out the oven. Any small 'chips' left behind were gently sanded down flush.

It did help having two pairs of hands to keep the lens straight and in position when joining the glued up surfaces followed by gently taping up with masking tape.

Post up some pics when you can.

Hi
 

Great info, thanks

But what bothers me about the Dansk lens are the color, they tend to favor a pick color

Think you meant 'pink'(?) To be honest I can't say I noticed the Dansk lens we worked with as being more pink than the original - mind you after 20 years of sunlight the original looked very tired and pink.