How do I replace the headlight assembly?

rocketman7 · 10-25-2006, 11:02 PM

So I'm driving down the highway to the hospital to meet my wife who just went into labor and WHAM - something hits the front end of my car (drivers side) and bounces off the headlight. Later on (and one baby boy later) I look at the light and see that it is deeply scratched and the interior plastic is broken along with a burnt out turn signal. I purchased a used headlight assembly (ebay) but how in the heck do I get the old one off? I took out the two 10mm screws holding it on but it won't budge....anyone have any experience with this?

Beryl Octet · 10-26-2006, 09:56 AM

<div class='quotetop'>QUOTE(rocketman7 @ Oct 25 2006, 11:02 PM) [snapback]338388[/snapback]</div>

Quote:

So I'm driving down the highway to the hospital to meet my wife who just went into labor and WHAM - something hits the front end of my car (drivers side) and bounces off the headlight. Later on (and one baby boy later) I look at the light and see that it is deeply scratched and the interior plastic is broken along with a burnt out turn signal. I purchased a used headlight assembly (ebay) but how in the heck do I get the old one off? I took out the two 10mm screws holding it on but it won't budge....anyone have any experience with this?
[/b]

If you have the replacement one in hand, can you see any places on it that look like they could be brackets for additional bolts, or clips where it might just snap in, etc.? I'd hope this would be a simple repair for you, but you never know.

Allannde · 10-26-2006, 01:05 PM

<div class='quotetop'>QUOTE(rocketman7 @ Oct 25 2006, 06:02 PM) [snapback]338388[/snapback]</div>

Quote:

So I'm driving down the highway to the hospital to meet my wife who just went into labor and WHAM - something hits the front end of my car (drivers side) and bounces off the headlight. Later on (and one baby boy later) I look at the light and see that it is deeply scratched and the interior plastic is broken along with a burnt out turn signal. I purchased a used headlight assembly (ebay) but how in the heck do I get the old one off? I took out the two 10mm screws holding it on but it won't budge....anyone have any experience with this?
[/b]

The '06 Manual says first disconnect the negative ground of the 12v battery then wait 90 seconds to prevent activation of the seat belt and airbags, then remove the fender liners, then remove the bumper cover, then remove the three screws and pull out the headlight toward the front of the vehicle. Then there is a long list of instructions for disconnecting connectors and removing bulbs.

Do you have a self leveling system in your headlights? If so, this adds to the complication of R&R becaused that must be reset and readjusted.

Remember when you reconnect the battery you will need to perform an Initiaization. You will also need to restore any electronic instructions you have given to the car such as "beep" removals as they will return to the their default settings.

Are you sure that the headlight you purchased matches the one on the other side of your car? I am referring to the light it makes not the fit to the car even though they both matter.

By the way Congratulations on the new baby boy!!!!!

Beryl Octet · 10-26-2006, 01:20 PM

I take back what I said about this should be a simple repair. Remind me to be really careful with my headlights. I replaced one on my Tundra, it seemed to almost snap in. Well, actually that procedure doesn't sound that bad, but definitely more like "free afternoon" than "spare 20 minutes." Do you have to go back to the dealer for the HID levellling setup, or can that be done by a DIYer without special tools? I'm interested becuase I seem to need a windshield or headlight lens at least every other year on one of our cars.

rocketman7 · 10-26-2006, 08:43 PM

<div class='quotetop'>QUOTE(Beryl Octet @ Oct 26 2006, 06:56 AM) [snapback]338546[/snapback]</div>

Quote:

If you have the replacement one in hand, can you see any places on it that look like they could be brackets for additional bolts, or clips where it might just snap in, etc.? I'd hope this would be a simple repair for you, but you never know.
[/b]

There looks to be a third connection on the lower front end that is covered by the bumper/fender.

<div class='quotetop'>QUOTE(Allannde @ Oct 26 2006, 10:05 AM) [snapback]338659[/snapback]</div>

Quote:

The '06 Manual says first disconnect the negative ground of the 12v battery then wait 90 seconds to prevent activation of the seat belt and airbags, then remove the fender liners, then remove the bumper cover, then remove the three screws and pull out the headlight toward the front of the vehicle. Then there is a long list of instructions for disconnecting connectors and removing bulbs.

Do you have a self leveling system in your headlights? If so, this adds to the complication of R&R becaused that must be reset and readjusted.

Remember when you reconnect the battery you will need to perform an Initiaization. You will also need to restore any electronic instructions you have given to the car such as "beep" removals as they will return to the their default settings.

Are you sure that the headlight you purchased matches the one on the other side of your car? I am referring to the light it makes not the fit to the car even though they both matter.

By the way Congratulations on the new baby boy!!!!!
[/b]

I removed the fender liner but didn't want to go any further...sheesh! This is going to be an all day affair. They are the normal headlights (I have an '04) and the bulb is ok just the plastic assembly is damaged.

Thanks - the boy is doing great!

<div class='quotetop'>QUOTE(Beryl Octet @ Oct 26 2006, 10:20 AM) [snapback]338676[/snapback]</div>

Quote:

I take back what I said about this should be a simple repair. Remind me to be really careful with my headlights. I replaced one on my Tundra, it seemed to almost snap in. Well, actually that procedure doesn't sound that bad, but definitely more like "free afternoon" than "spare 20 minutes." Do you have to go back to the dealer for the HID levellling setup, or can that be done by a DIYer without special tools? I'm interested becuase I seem to need a windshield or headlight lens at least every other year on one of our cars.
[/b]

I don't have the HID lights so I thought I'd be able to do it myself. Maybe I'll have to subscribe to a one day pass to the Toyota Tech manual and download how to do it. The windshield would be a lot easier - insurance covers it and they come to your house and fix it for you...

galaxee · 10-26-2006, 08:46 PM

you have to take the fender liner out. then there is a screw near the edge of the bumper in the fender, that holds the bumper cover to the fender. take that screw out. then you can pop the bumper cover out away from the fender, and there will be a 3rd 10mm bolt there. take that out too.

next step, unplug all wire from it and CAREFULLY slide it out. don't force it, but it won't just slide off like nothing. you're supposed to remove the whole bumper cover but that's a huge affair and you can get away with this.

i think you should be able to get the rest from there.

congrats on the new son! let us know how the replacement goes.

hobbit · 10-27-2006, 12:01 AM

I believe it's possible to get at the third headlight-assembly bolt
by simply loosening enough of the fender-liner and the big plastic
front schnoz piece to pull them slightly aside. We did this at the
last tech-training thing; it was actually fairly fast. But you do
have to get behind there just enough to unbolt it.
.
Experienced auto techs are good at finding all kinds of shortcuts
for only partially loosening things that are in the way and shifting
them aside, but at the occasional expense of bending them in funny
ways. My own LHS fender-liner got a little mangled a month or so
ago when one of the trainees *really* wanted to have a look at the
thermos bottle and he was somewhat ham-handed... it's only plastic,
but some guys aren't quite as careful as they should be.
.
_H*

rocketman7 · 11-22-2006, 04:08 PM

Well, I finally got around to replacing the headlight assembly (long work days and nights caused the delay). As previously suggested, partially removing the bumper did the trick. It was a little bit of a pain to switch the bulb, but after fumbling with that for a while it's switched out too. After putting it all back together, it looks great. The only question now is what's the best way to adjust the beam. There is a 'thumb' screw but other than pointing the car at a wall I don't know of any other way.

Thanks again to those who helped,

Sam

10-26-2006, 08:46 PM	#6
galaxee science runs my life Join Date: Mar 2005 Location: maryland Posts: 9,763 My Car: 2005 Prius Model: N/A Package: #5 Thanks: 0 Thanked 151 Times in 56 Posts Friends: 27	you have to take the fender liner out. then there is a screw near the edge of the bumper in the fender, that holds the bumper cover to the fender. take that screw out. then you can pop the bumper cover out away from the fender, and there will be a 3rd 10mm bolt there. take that out too. next step, unplug all wire from it and CAREFULLY slide it out. don't force it, but it won't just slide off like nothing. you're supposed to remove the whole bumper cover but that's a huge affair and you can get away with this. i think you should be able to get the rest from there. congrats on the new son! let us know how the replacement goes. __________________ black 2005 prius, a few mods that make me happy proudly doing the science to better serve those who serve our country

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10-25-2006, 11:02 PM	#1
rocketman7 Member Join Date: Feb 2004 Location: Central Coast California Posts: 62 My Car: 2004 Prius Model: Package: #3 Thanks: 0 Thanked 4 Times in 4 Posts Friends: 0	So I'm driving down the highway to the hospital to meet my wife who just went into labor and WHAM - something hits the front end of my car (drivers side) and bounces off the headlight. Later on (and one baby boy later) I look at the light and see that it is deeply scratched and the interior plastic is broken along with a burnt out turn signal. I purchased a used headlight assembly (ebay) but how in the heck do I get the old one off? I took out the two 10mm screws holding it on but it won't budge....anyone have any experience with this?

10-26-2006, 01:20 PM	#4
Beryl Octet Senior Member Join Date: Aug 2006 Location: Abingdon VA Posts: 1,294 My Car: 2005 Prius Model: Package: #4 Thanks: 0 Thanked 0 Times in 0 Posts Friends: 0	I take back what I said about this should be a simple repair. Remind me to be really careful with my headlights. I replaced one on my Tundra, it seemed to almost snap in. Well, actually that procedure doesn't sound that bad, but definitely more like "free afternoon" than "spare 20 minutes." Do you have to go back to the dealer for the HID levellling setup, or can that be done by a DIYer without special tools? I'm interested becuase I seem to need a windshield or headlight lens at least every other year on one of our cars.

10-27-2006, 12:01 AM	#7
hobbit Senior Member Join Date: Mar 2005 Location: Bahstahn Posts: 4,087 My Car: 2004 Prius Model: N/A Package: Base Thanks: 0 Thanked 419 Times in 222 Posts Friends: 0	I believe it's possible to get at the third headlight-assembly bolt by simply loosening enough of the fender-liner and the big plastic front schnoz piece to pull them slightly aside. We did this at the last tech-training thing; it was actually fairly fast. But you do have to get behind there just enough to unbolt it. . Experienced auto techs are good at finding all kinds of shortcuts for only partially loosening things that are in the way and shifting them aside, but at the occasional expense of bending them in funny ways. My own LHS fender-liner got a little mangled a month or so ago when one of the trainees really wanted to have a look at the thermos bottle and he was somewhat ham-handed... it's only plastic, but some guys aren't quite as careful as they should be. . _H*

11-22-2006, 04:08 PM	#8
rocketman7 Member Join Date: Feb 2004 Location: Central Coast California Posts: 62 My Car: 2004 Prius Model: Package: #3 Thanks: 0 Thanked 4 Times in 4 Posts Friends: 0	Well, I finally got around to replacing the headlight assembly (long work days and nights caused the delay). As previously suggested, partially removing the bumper did the trick. It was a little bit of a pain to switch the bulb, but after fumbling with that for a while it's switched out too. After putting it all back together, it looks great. The only question now is what's the best way to adjust the beam. There is a 'thumb' screw but other than pointing the car at a wall I don't know of any other way. Thanks again to those who helped, Sam