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Old 12-04-2021, 06:21 PM
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The mysterious bulb carrier

My 2002 E53 has some tail light issues. I just found out the joys of identifying bulb carriers. Nightmare at minimum. Only buy one at a time, at most a pair. But buy them cause you probably need them !
I really don’t think the lights on my tailgate have ever worked. Local parts establishments don’t even have a listing for the parts. (Bulbs and carriers) I’m way too excited about this

Anyway thanks for any advice, guidance, or commiseratance would be appreciated.
Mike
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Old 12-04-2021, 06:24 PM
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A direct replacement will have the same design defect. I rebuilt mine with steel screws and shims to eliminate the self destruct nature of steel contact held by plastic which melts.
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Old 12-04-2021, 07:21 PM
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I lube mine up heavily with dielectric grease so no corrosion causes the contacts to get bits of resistance and start melting...
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Old 12-04-2021, 08:26 PM
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Hey Andrew, how ya doin ? Thanks, liketo see your upgrade details.
Thanks rocket, that’s a really good idea, probably lubricates to help assembly and prevent those cursed terminal s from breaking.
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Old 12-04-2021, 08:53 PM
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https://xoutpost.com/1047563-post65.html

Just a couple pics I have about six pics but would take a while to find
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Old 12-06-2021, 02:43 PM
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That's a good fix idea! So Andrew, from your reference post, I'm guessing you sorta pre-drilled the plastic that stuck a short sheet metal screw in there to fasten it?

Can you recall what drill bit size you used and exact screw size as to not crack the housing and such?
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Old 12-06-2021, 03:20 PM
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I added a little bit of solder at each contact point location. That creates tension against the metal part on the bulb carrier so you don't get any shorting. A very poor design on BMW's part.
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Old 12-06-2021, 03:37 PM
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Quote:
Originally Posted by RocketyMan View Post
That's a good fix idea! So Andrew, from your reference post, I'm guessing you sorta pre-drilled the plastic that stuck a short sheet metal screw in there to fasten it?

Can you recall what drill bit size you used and exact screw size as to not crack the housing and such?

Idrilled out all the plastic rivets I used about ¹/₈" bit which is a moot point. I used self tapping screws probably size #8 to fasten after that drilled into the plastic with a big enough hole to not split.

I used a heat proof shim under to hold the spacing correct so even if it gets hot it won't melt the plastic holding things.


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Old 12-06-2021, 03:38 PM
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Quote:
Originally Posted by Fifty150hs View Post
I added a little bit of solder at each contact point location. That creates tension against the metal part on the bulb carrier so you don't get any shorting. A very poor design on BMW's part.

Using steel as a contact was a terrible idea as always. Putting a little silver solder where the contact goes is a good idea. Silver "rust" is conductive why copper contacts often are silver plated.

Lead/zinc solder prob not the best contact but beats steel
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Old 12-06-2021, 06:54 PM
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Quote:
Originally Posted by andrewwynn View Post
Idrilled out all the plastic rivets I used about ¹/₈" bit which is a moot point. I used self tapping screws probably size #8 to fasten after that drilled into the plastic with a big enough hole to not split.

I used a heat proof shim under to hold the spacing correct so even if it gets hot it won't melt the plastic holding things.


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Awesome! The exact information I needed to know. Hopefully this will help out the OP if he choses to go that rout in terms of the repair.
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