Replace clear lexan headlight cover advise...
 

I think my BMW 2008 X5 has the Zenon Bi-Directional Headlights (they move slightly when I start the car). Next spring, I want to replace the passenger side headlight cover - just the clear Lexan cover but not the complete headlight assembly. The headlights are still plenty bright enough...but the passenger side headlight has lots of surface scratches & lots of internal hairline cracks. A polish kit obviously won’t remove the cracks. The headlights are over $1800 each at RockAuto - yikes!. The clear replacement covers are about $40 each on Amazon. I watched some YouTube videos and it looks like it’s not that difficult but requires that you remove headlight and heat up the headlight slightly with heat gun & cut the clear headlight cover off the rest of the assembly. Then clean up the surface and re-glue the new cover on.

Has anyone done this task on the X5 and any advice? I searched the forums but couldn’t find much. Thanks for your assistance.

Yes, I have. Best to do both sides as if you only do one side it will be very obviously different. The process is tedious and painful to your fingers, but it's doable and is a very rewarding upgrade.

BTW, you can skip the heating phase. Doesn't do anything except make the headlight body too hot to touch. Just cut the old lens out and then clean the U-channel that the lens sits into. That's the part that takes the most time. Took about 4 hours of cleaning out the residual old lens and silicon adhesive per headlight. Not fun.

Thanks for the information. What did you use for glue or sealant to install the new covers?

Regards

From memory when I had to replace a ballast, removing the headlights is oddly complicated. There are some bolts on the back that will require removing the fender liner and IIRC there is a very awkwardly placed screw near the radiator that has very limited space to reach. Before starting, check that you have enough oddball tools to reach in and remove all the fasteners. :)

Agree, it's a terrible setup. I broke one of the plastic "slider" guides that is supposed to align the headlight in the fender on the LHS headlight. I have to take the RHS out again now to replace the lens like the other side and do the new halos. I'm sure I'll brake that side now that it has to come out again. :rolleyes:

Use butyl rope to reattach your lenses OP. I used this stuff. Works very well and have never had any leaks. It's thick stuff and is difficult to lock the lenses back in place, but I'd rather have that issue than leaking and blowing out one of the headlight electronic components (had that experience once before on a different vehicle).

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

Thanks for the information and the link on the butyl rope - I’ll have to order that stuff soon.

On a BMW?

How weird...


:cool:

I replaced the lenses on my 07 X5 and echo the previous comments.
I found that a cheap heat gun did assist in softening up the adhesive in the channel holding the lens. Didn't need to get it to hot to touch, just warmed it up a bit.
I also ground down a flathead screwdriver to fit the channel to help me get under the adhesive without tearing up the light.
Take the time to blow out all the tiny pieces of plastic before you put the new lens on. The stuff hids out in all the crevices in the light.
Wish I would have changed out the halos while I had it a part.
With the driver side fendor liner out, don't drive the car without zip tying the wiring harness above the wheel. It droops down and rubs the wheel once you get going.

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I replaced the lens on my X5. Getting the headlight assembly out is complex, especially the right side. My recommendation- use a dremel to cut the old lens, leaving about 1-2 inches. Then use a heat gun or hair dryer to soften the old sealant and pry out the remaining piece. It’s a LOT easier this way than trying to wrestle the entire lens. Figure 8 hours minimum per side. Seriously.

Yeah, I know, who woulda thunk? :)