HID Headlight Replacement snag - please help

The first time I removed my covers they were very tight to turn at first to the point where I thought something would break . It would probably be better if you removed the lamp complete this first time and lubricate the seals with silicon spray before putting them back on.

John (Britprius0

 

I just did this repair, first one for the 2005 my wife just bought. She didn't notice the headlight was burnt out when she bought it! She didn't notice a lot of things...

Things expand when they get hot. One way to free a stuck bolt is to heat it with a torch or heatgun. Works well with something with a high coefficient of thermal expansion, like aluminum or ... plastic! Not only does plastic expand a lot with heat, it gets softer and less brittle. After struggling with those covers for half an hour, I ran a hair dryer on them for a minute or two. Opened right up after that.

I'd be careful with penetrating oil and the like. It will attack rubber seals and there are o-rings on the covers. I don't think the hairdryer got them any hotter than they would get under baking in the summer sun someplace hot.

You can find a video on youtube where they remove the whole assembly and do the change with it off the car. A lot more work, but the video gives you a clear look at the parts you're working with by feel.

I found the hardest part was getting the bulb connector on and off on the driver's side. Other side was easy. Be sure to note the orientation of the connector when it's locked and when you've turned it enough to get it free. It will make it a lot easier to line up when reinstalling.

 

I did this to my 2005. I also watched the Luscious Garage video and finally concluded her hands are smaller than mine. I had to drop the bumper, just top edge, and pull the light. Its easy after you do that.

 

Just replaced both HID bulbs in my 2009. I also had a tough time opening the seal on my driver side - actually broke off a tab in the process. Was about to give up and drop the bumper but decided to take a break and then give it another shot - glad I did. Passenger side was easier to get off but both required constant/slow force.

I agree with BritPrius' suggestion of using silicone grease on the rubber seal to make it easier the next time around - thought about doing that after I finished buttoning everything up. To xyzzy42's point about penetrating oil that attacks rubber, silicon based lube does not attack rubber - it is often used to lubricate and preserve rubber. hydrocarbon based lubricants on the other hand are not compatible with rubber and should not be used (wd40 for example). Next time I have it open I'll definitely be applying some silicone grease.

 

An. Reading this makes me really appreciate the thought of service that goes into our Volvo's. My wife's has access similar to a Prius until you realize the entire headlamp is held in place by two quick release brackets. 10 seconds and the entire lamp is out, with full access. Take note Toyota!