Question about 1989 Peugeot 405

2 Answers

I need to replace front headlamp lens peugeot 405 1992

Had to buy whole new headlamp assembly from scrapyard. cannot see how to remove old assembly (bolts at bottom inaccessible). thought about unclipping lens from new assembly but cannot see how fit clips(underneath and to the side) back on

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  • Joe Bloggs
    Joe Bloggs Jul 15, 2015

    The headlight lenses CAN be unclipped and put back again. I've just done it as I needed to spray the brown reflectors back to silver! Unclip indicator lamp, remove radiator grill (tiny hidden Torx screws) then lever out the trim underneath the headlamp. Its actually more difficult than this as the trim will probably break and need to be glued back together. FWIW the lamp screws are 10mm AF. For the lower ones advanced tooling is needed such as 1/4" drive socketry and wobble-bars, obstruction spanners etc and of course a ton of patience! The other way is to remove the bumper but the bolts may be extremely rusty and very difficult to undo.

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Allegedly the bumper has to come off! Duh! I've got a dim headlight as a result of a tarnished reflector but getting the old one out is such a pain that it might be clips-off and cooking foil or silver spray paint Presumably headlamp removal is deliberately made difficult to in order to deter headlamp theft. (In the Midlands of the UK there was a spate of headlight thefts from 4x4s because the headlights were merely clipped into place. AFAIK nobody was ever caught.).

Posted on Jul 14, 2015

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Phone the scrapyard you bought it from, they had to take it out and having had your business, will hopefully be helpful!

Posted on Feb 17, 2011

  • prioryeng Feb 18, 2011

    having just had the same problem myself here is what i did, its not the book way but its quick if you have bought a complete replacement assembly, not just the lens. i had a knock to the offside front corner which broke the lens and, when i too bought a complete £10 scrappy replacement i undid the two o/s and inner n/s cluster bolts and 2 lower star screws allowing front grille to come off and trim to be prised away under lamp. on closer inspection i found that the knock had sheared off the plastic mounts of the 2 lower cluster bolts and so the assembly, once the indicator lamp spring and all wiring plugs had been disconnected, could be eased out . if the lower bolts had had to be 'conventionally' removed i think the bumper would have needed taking off. with no lift available this was a haynes spanner too far for me,. so i refitted the new assembly using only 2 upper bolts, and it seems fine and stable. so, if you have a complete new assembly (check the headlight levelling plug is the right one first - is it black or brown , wide or narrow?) simply take out any good bulbs and the upper bolts, then bludgeon the assembly till you break the mounts (messy but satisfying), take out the bolts and replace by easing new one in over top of bumper and securing with just the 2 upper bolts

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SECTION 417-01: Exterior Lighting 2000 Focus Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 03/6/2003
Headlamp Assembly Removal
All vehicles
  1. Remove the fender splash shield lower retaining screw.
    • Push the fender splash shield to one side.
    e0014434.jpg
  1. Remove the headlamp assembly lower retaining bolt.
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  1. Remove the radiator grille.
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Vehicles built up to 07/1999
  1. Remove the headlamp assembly.
    • Disconnect the headlamp assembly electrical connector.
    e0022744.jpg
Vehicles built 07/1999 onwards
  1. Remove the headlamp assembly.
    • Disconnect the headlamp assembly electrical connector.
    e0030083.jpg
Installation
Vehicles built up to 07/1999
NOTE: Procedure if there is a concern over the formation of condensation inside the plastic headlamp lens or if the plastic headlamp lens is split.
NOTE: It is normal for a small amount of condensation to form on the inside of the plastic headlamp lens, it will disappear when the headlamp is switched on. If the headlamp does NOT dry out after having been switched on for 15 minutes, check the build date of the headlamp. If the build date is between 01.08.98 and 30.09.98, install a new headlamp cover flap.
NOTE: If there is a concern, both headlamps must be removed. Defective headlamps must be renewed and reworking may be necessary. When the headlamp is installed, the number of mounting points must be reduced.
  1. If the headlamp assembly is defective, install a new one.
  1. NOTE: Sometimes the guide pin on the plastic headlamp lens is still present on a new headlamp assembly.
    Cut off the guide pin flush and de-burr as necessary.
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  1. Remove the headlamp levelling motor from the faulty headlamp assembly and install it on the new headlamp assembly. For additional information, refer to Headlamp Leveling Motor - Vehicles Built Up To: 10/2001 in this section.
  1. NOTE: Sometimes there is no hole in the bracket of a new headlamp assembly.
    Do NOT install the retaining bolt any more.
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All vehicles
  1. NOTE: Fix the headlamp assembly in place using the locating pin.
    Install the headlamp assembly upper retaining bolts.
    • Connect the headlamp assembly electrical connector.
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  1. Install the radiator grille.
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  1. NOTE: Fix the headlamp assembly in place using the locating pin.
    Install the headlamp assembly lower retaining bolt.
    v9610258.jpg
  1. Install the fender splash shield lower retaining screw.
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  1. Adjust the headlamps. For additional information, refer to Headlamp Adjustment - in this section. For additional information, refer to Headlamp Adjustment - Vehicles With: High Intensity Discharge Headlamps in this section.

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3 Answers

Can you just replace the headlamp or do you have to do the whole headlight assembly?


Those are sealed unit headlamps, you need to replace the entire headlamp, not the bulb.

There are 4 screws on the trim ring, don't confuse the aiming adjusters. Remove the 2 bottom screws, then one of the top screws. While holding the headlamp in place, remove the last screw. Hold the headlamp out far enough to be able to unplug it carefully. Then just reverse this to put the new one in. There is a top and bottom on the headlamp, (make sure you can read the name on the headlamp lens) and on the trim ring (make sure the holes line up.

It would also help to buy some silicone bulb grease for the connector, this'll keep it from corroding. Just smear some grease on the prongs before you connect the new headlamp.

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1 Answer

When you turn the headlights on everything works but the headlights. If you hold the dimmer switch in the brights will come on. When you let it go the lights go out


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REMOVAL & INSTALLATION Sealed Beam NOTE: If vehicle is equipped with headlamp doors turn the headlight switch ON. Open the hood and locate the power distribution center. This center is located in the front of the left front strut tower. Remove the cover from the center and remove the Headlamp Close Relay. This will prevent the headlamp doors from closing to provide easier servicing. Turn the headlight switch to OFF, then perform this repair.
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Aero Headlamp Aero headlamp systems use replaceable halogen bulbs that are mounted in aerodynamic, molded plastic lens reflector assemblies. NOTE: Lens fogging is a normal condition and does not require service, as moisture will vent from tubes behind the lens on Aero headlamp-type system. EXCEPT PREMIER AND MONACO It may be necessary to remove the entire headlamp assembly if enough access cannot be gained otherwise.
  1. Locate and remove the wire connector behind the headlamp assembly in the engine compartment. It may be necessary to remove certain items in the engine compartment to gain access to the bulb wires.
  2. Rotate the bulb retaining ring counterclockwise 1?4 turn and remove the ring, bulb and bulb holder from the lens assembly. The bulb holder has alignment notches. NOTE: Do not touch the bulb with bare fingers or any possibly oily surface, since reduced bulb life may result! Fig. 1: To remove the light bulb, first unplug the headlight electrical connector, then . . . 86726p13.jpg
    Fig. 2: . . . remove the light bulb socket retaining ring 86726p14.jpg
    Fig. 3: Rotate the light bulb socket 1?4 turn counter-clockwise, then pull it straight out of the lens assembly 86726p15.jpg
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PREMIER AND MONACO Unlike the other vehicles covered by this manual, the removal and installation of the headlamp bulbs in the Premier and Monaco models requires the extraction of the entire headlamp lens assembly.
  1. Remove the grille-to-headlamp assembly attaching screws.
  2. Disconnect the headlamp aiming cable from the aiming screw end.
  3. Remove the headlamp assembly attaching bolts from above and behind the lamp assembly and separate the lamp assembly from the vehicle.
  4. Unplug the headlamp wire connector. NOTE: Do not touch the bulb with bare fingers or any possibly oily surface, since reduced bulb life may result!
  5. Rotate the socket counterclockwise 1?4 turn and pull the socket from the back of the lens assembly. Fig. 4: Remove the bezel retaining screws to loosen the headlamp assembly - Premier and Monaco 86726g91.gif
    Fig. 5: Detach the headlamp wire connector - Premier and Monaco 86726g92.gif
    Fig. 6: Once the headlamp assembly has been removed from the vehicle, the various light bulbs can easily be removed - Premier and Monaco 86726g93.gif
    To install:
  6. Wearing gloves or holding the replacement bulb with a cloth rag to keep oil off of the bulb surface, insert the bulb into the rear hole of the headlamp assembly. Make certain that the alignment grooves and tabs line up, push the light bulb into the assembly until seated flush, then turn the bulb clockwise 1?4 turn.
  7. Plug the headlamp wire connector back into the headlamp bulb.
  8. Install the assembly into the vehicle and secure in place with the mounting bolts.
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REMOVAL AND INSTALLATION Lamp Assembly —Headlamp, Aerodynamic Removal
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      • d1d723b.gif

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1 Answer

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  2. Remove the mounting screws for the lamp assembly.

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Remove the mounting screws securing the lamp assembly

  1. After the screws are removed, pull the assembly from the vehicle.

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After the screws are removed, pull the assembly from the vehicle

  1. Disconnect the twist lock socket from the lens housing.

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Disconnect the twist lock socket from the lens housing

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Newer Oldsmobile models have the turn signal separate from the headlamp assembly ...


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... unlike the newer Buicks, where the unit is attached to the headlamp

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1 Answer

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Things You'll Need:
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Instructions
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1 Answer

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