Thread: D2a Headlights - separating using oven at 90*C

It's always better to repair than replace and you will learn other skills as you go, great work thanks for posting it.

Originally Posted by twr7cx

Just a quick one for anyone in the future that may be looking to do similar:

Putting the D2a headlights into an oven for 5 or so minutes at 90*C (I tried 10*C increments from 60*C to find this) made them very easy to seperate. The heat was not hot enough to melt anything of the light, it was still able to be held by naked hands once removed from the oven for the separating process, yet was hot enough to loosen the sealant that holds the clear lense on.

After removing the two screws two large flat headscrew drivers were sufficient to lever it apart.

Before putting it in the oven I did remove the globes and their change caps.

For anyone interested in my reason for doing this, its because I have cracked the backing case which had allowed in some dirt inside the unit during my last trips off road. I've pulled it apart to clean internally and am currently resealing with Sikaflex.

Interesting process. My Falcon ute has a cracked lens and a new light unit is $289 from the Ford dealer. I wonder if I can separate it from the reflector and patch the crack on the inside with super glue or similar.

I saw this done on a D3 light using a microwave, will save scrapping an otherwise good light.

I've done a few carefully using a heat gun , including a falcon and a couple of bmw e46
Don't think I'd be using a microwave as I can't imagine it doing much for the reflective coating on the light or the microwave much good

Originally Posted by loanrangie

I saw this done on a D3 light using a microwave, will save scrapping an otherwise good light.

I’d be cautious about that given that there is a variety of metal parts inside from screws to globe holders, which might cause an issue...