Replacing headlight lens on a 1994 850

Post by **lext** » 31 Jan 2011, 13:33

My first write-up. I'm picking the easiest thing to write about so I don't mess it up somewhere

Ok, so my front passenger side headlight lens has a lot of cracks in it. [In NY's accent] Whatz the big deal, 'aam sure it would have laasted another 10 yeers[/End accent]. Well, until I realized that I can replace just the lens for the cost about $30. There goes my excuse for waiting another decade

I ordered the thing and went straight to the Internet for instructions (seems like I can't do anything w/o instructions anymore

) I saw some posts telling me that for certain model of car I'll need to take off either the bumper, or at least the whole headlight assembly. What? Is it that hard? Come on, it's just the lens!

I then went about to find another way that involves no ratcheting (not saying this is better or worse, but for me it's just easier):

First take off the side signal assembly. This is only held in place by a small spring with a clip-on hook. It'll help if your hand is nimble and there's lot of light, but it's otherwise pretty easy (you'll have to do it if you ever replace the signal bulb, by the way).

: hl_signalon-3.JPG (278.27 KiB) Viewed 6174 times

Then take off the mini-bumper right below the headlight. This thing is held in place by a series of clips, some with a little hook backward (like in a fish hook). You can easily spread open the clip with a bent-nose pair of pliers like I did. Or if you're into brute force, yanking it out seems to work too (no real damage as far as I can see). Of course, as with everything else in life, try the gentler way if you can

: hl_signalon-2.JPG (294.49 KiB) Viewed 6174 times

: hl_signalon-0.JPG (278.58 KiB) Viewed 6174 times

Once that thing is out, open all the clips holding the lens in place. Again it'll help if you have the bent-nose pliers. This is the lens after all the clips are off:

: hl_signalon-1.JPG (293.16 KiB) Viewed 6174 times

Now put the new plastic damper/gasket and the new lens in, and try to put the clips back on. The first one will seem tough, as in "how the hell can this ever fit?" But once you realize it can be done, you'll find it's easier than you thought 5 mins ago

This pix is when all the clips are in:

: hl_signalon-4.JPG (273.28 KiB) Viewed 6174 times

The rest (putting back the mini-bumper and the side signal) is just routine.

Btw, I saw someone mentioned that they replace both lens at the same time so it looks the same. I didn't see that before I ordered (one lame excuse to save me $30

), but you can do that too.

Post by **jblackburn** » 31 Jan 2011, 16:57

Thanks for the contribution; we will add this into the repair database!

zhenya · Post by **zhenya** » 31 Jan 2011, 17:03

I'd like to add that if you are doing both, this is a great opportunity to switch to E-code lenses which will GREATLY improve the headlights on the 850!

Post by **patrioty3k** » 10 Apr 2011, 10:00

By the way,lext,where did you buy the lens cover for $30....?FCP has them for $39....thanks

Post by **kcodyjr** » 10 Apr 2011, 11:08

I've been told you're better off using the OE gasket if it's intact.

I didn't, and had to remove and reseat the aftermarket gasket twice, it was letting moisture in.

Post by **patrioty3k** » 14 Apr 2011, 15:39

gasket?i was wondering where u got the replacement lens........tia!

Post by **lext** » 14 Apr 2011, 22:33

patrioty, you're right, my mistake, it was $40 (39.99). Not sure where I got that $30 from, I think maybe I bought it and then I checked some other websites and found it cheaper elsewhere. But like others have said, you should probably go up to E-code.

kcody, I'm not sure if it's the clips. I actually used both, most old ones and some new ones. I think as long as it feels as tight as before then it's ok. Some of the old clips have something like a little (metal?) block soldered to the inside, I think it's there for a reason but sometimes it can be tough to put back.

Post by **BEJinFbk** » 15 Apr 2011, 12:07

The factory gasket is continous - one big loop. Good Stuff!
The ScanCrap is just a long strip, so you end up with a gap...
I just reused my OEM gasket and it's bone dry in there.

zhenya · Post by **zhenya** » 15 Apr 2011, 12:25

I'm going to take this opportunity to correct the advice I gave earlier in the thread. After a significant amount of research and testing this past winter, trying to maximize my lighting for the Winter Rally series I participate in (held entirely at night), it turns out that the best lights for the car are (wait for it...) the stock Hella units. Not only does putting the e-code lenses on the US-spec reflectors do weird things to the bulb focus, but the cheap aftermarket lenses are not produced to nearly the same rigid specifications as the OEM Hella glass. I used the e-code lenses for several years, and while the high beams were excellent, I could never get the low beams aimed properly high. After consulting several industry experts, I was convinced to go back to the stock lenses, and with quality bulbs and proper aim, my low beams are much improved. (Highs are also still excellent).

FWIW, the Scan-tech gaskets I took off (which had always leaked) were also completely melted to the lenses. Fortunately I still had the old stock gaskets, which were perfectly fine, and don't leak.

Post by **BEJinFbk** » 15 Apr 2011, 20:14

Maybe with the 850's, but when I swapped from stock DOT to SC E-codes
on my V70, the difference was night and day. Especially the low beams.
I'd also be very surprised if the reflectors were any different between
DOT and E code. It's the lens that does the heavy lifting.
At any rate, I'm glad you've got a solution you like.
That's the important part!