Thread: Removing the Perspex face from headlight module

Hi Landoman, I assume you are talking about removing the front clear from the black housing of the headlight. First question is it a D3 or a D4? D3's seem to be easier to separate. If you search the internet or disco3.co.uk you will find instructions on heating the assembly and very slowly separating them. It appears that the D4 uses a different sealant. I managed to get hold of a pair of damaged D4 headlights from a D4 that had a front end collision and played around with them. The casing got very soft before the sealant even showed signs of softening. Good luck with it.

It's a d4 .......I'll probably leave it be ....the clouding is only in one half .....so some time in the future the whole unit may end replacing from a wreckers
.what did you pay for the units you bought ..........

From memory it was $20-25 for the pair (friend of a friend who has a panel shop), broken lense on one, broken housing on the other but has working xenon's and ballasts, high beam and indicator globes, so have spares of those now. Mainly wanted them to figure out how to fit static bending/cornering globes, all sorted now but very fiddly work without opening the unit. Was able to use connector pins and bits of internal wiring to keep it neat and factory looking.

Had similar problem on the D4 , i used a soft cloth wrapped around bent wire to wipe it off , worked well . Previously i tried the wife's hair dryer but burnt it out after 10 mins and snuck back inside of course i denied ever using it : New front light L or R $1200 each from the dealers .

Originally Posted by rasinater

Had similar problem on the D4 , i used a soft cloth wrapped around bent wire to wipe it off , worked well .

I had a halogen blow/explode within the sealed headlight enclosure of my motorcycle once. After shaking all the bits out through the hole for the bulb (shaped like a traditional "V" fish trap), I also cleaned the front plastic of the haze using this method - bent coathanger with a soft cloth.

Thanks guys ....coat hanger looks the way to go

Also what is this "ballast " of which you speak ?

In the unit it has the zenon main headlight globe , the high beam and the indicators in the side part ........but what is the ballast and where is it

I could be wrong, but I think the ballast is the silver metal box part at the base of the glass bulb with the rubber base. (deduced from when I looked on eBay they sometimes just sold the bulb looking part for very cheap)

If you have xenon headlights there is a flat rectangular aluminium finned item mounted on the underside of the headlight body. Power (12V) goes to this through internal wiring then to the xenon bulb (32V fom memory).