[TheLongKhan]

Working out a few gremlins of my own...was hoping to try the clean & rinse job too. 

 

@MCL968 - Where is the location of the headlight relay? Does each headlight have a relay?

 

Thank you

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[MCL968]

It's in the fuse box and it's marked on the fuse legend.

 

There is one large relay that controls the movement of both lights. Pop the cover off and clean the contacts on both sides of the relay tab and see what happens. It doesn't hurt to clean the plug on the relay as well, but that's unlikely to be the source of the problem.

 

Good Luck!

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[TheLongKhan]

@MCL968 - Thank you! Do you have a preferred cleaning product/brand?

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[MCL968]

@MCL968 - Thank you! Do you have a preferred cleaning product/brand?

Nope, just some fine sandpaper, folded in half so both sides are abrasive (like in politics) and then I used some MAF cleaner because that's what I had on hand. Worked like a charm on the drive home tonight.

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[TheLongKhan]

The relay seems to be in very tight. Can I just pull it out?...seems to have 2 square relays under a shroud

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[MCL968]

Yes, wiggle and pull.

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[TheLongKhan]

Ok...I have sanded and cleaned the relays.  I still am having issues. (Passenger side has issue going down).  When i put the headlights in service mode the passenger side is noticeably stiff. Assuming this is an opportunity for a solid grease job.

 

What are the grease locations and what is the best method to get to them?  I purchased the repair manual(pdf via ebay) and am not impressed with the level of detail provided. (novice mechanic over here).  Have read many of you have had success with greasing...hope to join that club soon too. 

 

Many thanks.

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[MCL968]

Yes, that's a lubrication issue. You need to move the headlight as far forward as you can by pulling the pin under the hood and moving the headlight forward. Then look in there with a light and you'll see a series of joints, rods, and the motor. Lube all of the moving points including the bottom of the headlight itself.

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[TheLongKhan]

Yes, that's a lubrication issue. You need to move the headlight as far forward as you can by pulling the pin under the hood and moving the headlight forward. Then look in there with a light and you'll see a series of joints, rods, and the motor. Lube all of the moving points including the bottom of the headlight itself.

 

 

In order to really get to it it looks like i have to remove the mechanism. I greased the parts i could access (rods, joints, et) but i could not access the bottom hinge(headlight moved forward).  Do I have to remove the fog lamps to get to bolts to remove the headlamp/get access to the bottom hinge?  Thank you for your help.

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[MCL968]

I believe I accessed mine through the fender well after removing the air cleaner box. I seem to recall that there were holes in the well area that allowed you to see in and lube the mechanism once the air cleaner box and the front cover that fits around the box were removed.

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[dwsjung]

My headlights go up smoothly, but both sides are binding when retracting - left side more than the right side.  i can press them down with some effort.  Does anyone have idea on what is causing this issue ? 

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[oppositelock]

Same as what's been discussed here. Start with lubrication. Remove the short link rod between the motor and the raising/lowering arm.  It is a ball and socket joint on both ends with small locking pins that need to be removed first. Clean the ball on the motor shaft and the arm and clean out the old grease in the socket ends on the link rod. Add small amounts of new grease and reinstall.  While the rod is off check for free movement of the headlight assembly. This greasing is a maintenance item that frequently gets overlooked.  If that fails try the relay cleaning. Use the underside of the relay cover to identify, but it is a big relay in the upper left as you are standing with your toes at the left front tire.  If that fails, you may need a new relay, especially if you can hear it making noise while trying to operate your headlights. It is an old mechanical relay and deteriorates from sitting.  Mine did after sitting and had to replace it.

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[vineyardcowboy]

New member hear and old guy. So I just purchased a 968 with head light raising problems. The passenger side goes up but not the drivers side. I can hear a clicking sound about every two seconds from the drivers side headlight somewhere. So I'm guessing it's stuck. My question is, how do I gain access to that area and motor? Sure isn't as easy as an old Chevy that's for sure. As a side note neither lights come on. But tail and signal lights work. 

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[MCL968]

I would first pull the air cleaner box to get access to the area behind the lights. Then, using a flashlight and some spray lube, soak down all of the pivot points and hinges. Slide out the locks (the little tabs with the holes in them) and move them by hand. Lube the slide locks at the same time as they are always sticky.

 

Once they are free, clean the contact points and the tabs on the relays. See the above posts to locate and address the right relay.

 

This is a common problem as rain and dirt are always in the area where these little rods and the motors are located.

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[Roboman]

+1 on MCL re soaking the area with penetration oil. I didn't realize how those lock handles worked because they were stuck in place; oil them well and then pull/slide horizontally. Once the handle slides you'll be able to manually raise/lower the lights.

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[vineyardcowboy]

I made some progress as I got both lights to come on. Bad news is after closer inspection I believe the headlight motor is bad. At least I know it's not working properly. I need to remove it, but do not see how you can get your hand in there to take the nuts off??? Yes I have the headlight out and cover and have it as far forward as possible, but still not way to reach nuts. I must be doing something wrong? No one would build something so hard to remove. Help!

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[Waylander]

I can guarantee they build things ridiculously hard to do, changing a sidelight bulb on a continental GT requires the removal of the front bumper, A $700 job for a $2 bulb

Changing the Headlamp bulb on my daughters 2007 mini clubman required major surgery,

 

and the oil filter housing gasket on a RHD 968 is not far short of impossible, or putting the door handle plastic levers back on !!, 

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[vineyardcowboy]

Question... Those of you that have removed these headlight motors, how do you remove the pivoting arm the headlight is attached to after removing the headlight? I need the space to be able to work in there to remove my motor. The motor removal is straight forward. It's the arm that I see no way to remove. HELP! 

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[Waylander]

They are the small pop on ball joints


There is a fine wire clip / pin that holds them on


The pin slides in a tiny hole and the clip part clips round the neck of the joint where the rod screws in


If you look closely the same clips are used on the bonnet struts, a close look at those might give you the info you need


You can just see the clip on this image


https://uk.rs-online.com/mobile/amp/p/ga...lsrc=aw.ds

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