Headlamp Release Stripped

brentsmith · 10-25-2014, 10:48 AM

I just removed the left headlamp assembly and replaced the low beam lamp in my 2003 Boxster S. Then I tried to remove the right lamp assembly and found the release mechanism stripped. Has anyone had this happen and, if so, what did you do? Can you access the other end of the cam mechanism from the fender well?

Thanks.

Brent Smith
Snellville, GA

clickman · 10-26-2014, 10:32 AM

Interesting. To put enough force on that lever end to strip it could indicate some other potential resulting problem: e.g. bent arm and/or damaged groove in the bottom of the light assembly.

You could get a slightly smaller socket and bang it on the remaining stub where the stock tool no longer works. Once you get the light out you can see what else you might be facing, including how to replace the arm.

I don't see any way to release the light from the fender well.

brentsmith · 10-27-2014, 05:08 AM

After further thought on this, I believe that the Boxster 5mm socket may be the problem and may have rounded the shaft. I noticed that it jammed a bit on the left side and was a bit difficult to remove. The tolerances for the socket may not be the best. Since the smallest 1/4" drive socket I have is 5.5mm, I am picking up a 5mm Craftsman deep 6-point socket and will try that. If the result is the same, I'll try to tap a 3/16" 6-point socket on the end of the shaft.

According to Wayne's Boxster book, the release direction is to rotate top-to-the front and lock is top-to-the-rear (those are my words). The Bentley Boxster book doesn't say which is which. That is what I am going with.

Brent Smith
Snellville, GA

Don Z. · 10-27-2014, 06:02 PM

Here's a similar situation. I don't know who did this to me, but whoever it was is missing one of their sockets:

Went to change the bulb. Could not for the life of me get the tool on the end. The more I played with it, the more difficult it was to get the Porsche tool on the shaft. It almost seemed like it was trying to go "in" the shaft than on it. For a while there, I thought I was going on an allen head, so I tried a t-handled allen wrench.

Eventually got that to work... only to find that whoever was there first (did I have some service put in a new bulb?) did NOT use the tool that came with the car (probably not a bad choice) but instead used a socket. When they pulled their socket wrench, they left the socket behind.They then put the grommet back on the hole, and put the whole thing together, only to be found by me, several years later.

So here's the kicker... I wracked my brain trying to remember if I actually would have paid someone to change a bulb. Not likely. The only people who would have done such work on the car would have been the dealer my wife took the car to when I was deployed. I looked again at the socket. I don't own any Hazet sockets... Funny, I would have expected more attention to detail from the guys on Porschestraße.

Before going further, I'd get the part. It is held in by "E" clips. A sharp six point deep well socket should be able to grab it. The manual has a picture of which way to turn. Replace the shaft once you get it out...

brentsmith · 10-29-2014, 04:25 PM

The 5mm deep socket worked perfectly to remove and replace the headlamp unit. I initially used the information in the Bentley manual and in Wayne's Boxster book without even checking the owner's manual. The owner's manual actually has the best description of exactly which direction to turn the socket to remove/replace the headlamp.

Brent Smith
Snellville, GA