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Old 08-26-2013, 08:29 PM
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MrFixIt is on a distinguished road
Xenon headlight broken levelers fix?

I had to remove the driver's side headlight assembly in order to remove/replace the ABS module. When I reinstalled the headlight assembly I realized the lights were loose and pointed way low.

Upon inspection, I noticed that the two white plastic contact/adjustment points inside the assembly were either broken or deteriorated that they no longer hold the lights up.

My quest is, is it possible to apply some type of epoxy to those two contact points? Everything works just fine except for the lights pointing too low. Hate to have to buy a new assembly if a simple epoxy can fit. This is for xenon headlight with self-leveling. 2003 4.4.

Thanks in advance.
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Old 08-30-2013, 04:15 PM
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It's fixed...I think. See Photos.

Decided to go with the $6 epoxy solution instead of $800+ for a new assembly.

Problem: internal light assembly would not secure in place due to worn or out of spec elevation and windage adjustment knobs that are located inside the assembly. See photos. Lights were pointed way too low and were leaning too far forward almost touching the front cover (should be set back a couple of inches). The two adjustment connectors were disengaged and would not stay secure no matter how hard they're pressed in.

My solution: Apply small amount of plastic epoxy around the ball joints and press the light assembly into the ball/socks and secure for a few minutes for the epoxy to set.

Everything is tight and the alignment is straight (might need minor adjustment tonight).

Only time will tell if this method is a longer term fix...

Last photo: I had to replace/repair the ABS Module. Removed the light assembly...probably pressed too hard when trying to discount the xenon connector.

Total cost of DIY repair: $150 for ABS module repair and $6 for the light.
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Old 08-30-2013, 04:28 PM
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Good work. Replacement adjusters can be purchased for about $10 a side, but replacement is not easy.
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Old 08-30-2013, 08:21 PM
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Location: Little Elm,Texas. (40 minutes North of Dallas)
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Sometimes the best fix is in a tube or on a roll.
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