alsamrob4

Just got the car out of storage after a suspension refresh, brake job and 90K service. One of my headlight lenses has a divot out of it. So I want to replace them prior to inspection.



When I went to remove the lenses, I notice that two of the tabs on each housing have what look like little screws with a washer holding the tab in. These are at 3 o'clock and 9 o'clock when facing the light. The hole is round. No hex bit will grip. Is the move to just pop them off? Don't want to do something that will sideline the car while I wait for a part.
I searched in vain for an answer. Any guidance is appreciated.

ed devinney

Those are actually where the plastic was melted to hold things together - carefully cut/snap and you're good.

alsamrob4

UPDATE: Pelican's Tech section states: "Two of the catches are "sealed" by a melted down plastic area. Gentle prying broke open the seals." That is the plan. Hope this helps someone else, like me, with limited Interweb and mechanical skills.

alsamrob4

Thanks for affirmation Ed. I'm a measure 3x, cut once person, so that gives me comfort

pp000830

The tabs can be very brittle. So slice the melted part off with care. If you crack one of the tabs it will still work.
Andy

alsamrob4

Thanks Andy. Best implement to free the tab? Should I heat up a utility knife? or just elbow grease and patience?

HalfGerman

I don't remember what I exactly did. But I think I sliced with a razor or exacto blade along the red line. Then using a pry tool or putty knife gently tried to lift the tab to the right of the red line

GJSPIN

I used a very small hand saw to break the seal then gently pried them open. By the way, I have nice pair of used lens available (for sale) if anyone is interested.

alsamrob4

Thanks all. Went relatively smoothly with a small screwdriver and Xacto knife. Once I got past the fact that I had to break the melted plastic I was less concerned about disabling the whole housing and went at it. 10 minute job for a guy with 10 thumbs.

pp000830

Hi Rob,
Any number of approaches will work.
Maybe a pencil soldering iron first to melt around the welded plastic and if that doesn't worry a mat knife or a moto tool cutting head.
The key is to work slowly and avoid or minimize cracking the clips.
Andy