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rusted/ now snapped headlamp aim screw

  #1  
Old 05-21-2018, 08:12 AM
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Default rusted/ now snapped headlamp aim screw

Good day to all, Mine is not so good! USA model 04 T&C here
Went to adj a low aiming pass headlamp and the adjuster bolt snapped off. Took the headlamp housing out and can not figure how to remove the aiming assembly from the housing. Thanks to our Northeast RUSTBELT area the main screw is rusted solid, along with having snapped off the aiming screw part.
Any help greatly appreciated!
 
  #2  
Old 05-22-2018, 07:54 AM
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Well, after 24 hrs of searching...I have not found replacement adjuster parts for these 01 - 07 headlights.Just replacement headlight assemblies. Looks like time to "rig" it as i had done with my past vans. A shame to replace whole headlamp units, as the lenses are otherwise in "perfect" condition(no lens scratches/dulling).
 
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Old 05-22-2018, 11:54 AM
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UPDATE: After disassembling one of the poor condition headlamps from my "parts" van. I was able to swap the adjuster assembly by drilling a small hole, close to the adjuster housing, to reach the retaining plate torx T-15 screw that holds the screw to the reflector.
Height adjustment is now possible, after cleaning and lubing all the adjusters parts. Waiting for the dab of RTV to cure to seal the small hole that had to be made, and the plastic epoxy to cure for the front outer plastic mounting tab for the light housing to body that broke while working on the disassembly of the seized aimer!
 
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Old 05-22-2018, 03:16 PM
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Glad you figured it out.
I had looked for an answer when I saw your post, but could not find anything on it in either the digital copy of the service manual for your van, or on the alldata domestic discs.
 
  #5  
Old 05-22-2018, 04:01 PM
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Thanks! Very frustrating for such a minor thing! But here in the RUSTBELT of the Northeast USA, quite a common occurrence, Just disappointed they don't make replacement adjusters.
The hardest part is drilling a small hole for a T-15 driver to unhook the unit from the reflector. The adjuster housing rotates 90* clockwise and will pop right out once disconnected from the reflector.
 
  #6  
Old 05-23-2018, 08:17 AM
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Went out last night and checked the beam pattern against a wall (and compared to the good align of the other headlight). Was only an inch too high from where I left the adjuster on reassembly! Lowered the the adjustment EASILY...all is MUCH better now!
 
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