Originally Posted by crazyjoe
Thanks for the heads up on not needing a dremel for the headlights (although the link you posted was for clearing the taillights, lol). I may invest in a cheaper rotary tool just for the fun of it, I'd like to see what all I can tear up with one, lol. How much does the B&D model run??
Heres the correct one from Tech Info...
2000+ models, follow this:
OK...here is the scoop. Yes, it can be done and rather easily (if you do it right).
What I mean by this is that taking the head lamp assembly apart and putting it back together takes some time. We aren't talking about cracking a walnut here.
To remove the headlamp, remove the one screw like the owner'* manual says (under bulb replacement). Take out the longer screw at the pivot point, disconnect all the bulbs and the lamp should pull out with a little wiggling back and forth, while pulling straight out.
Once the assembly is out, you will notice that there are 7 or 8 spring clips holding the clear lens to the enclosure. Using a small pair of needle-nose pliers and/or a large flat blade screwdriver, remove all the clips. Starting at the large end of the assembly, start prying the lens off. You may need a screwdriver to get it started. You will notice that the entire edge of the lense is coated with black silicon. As you start to get the lens away from the enclosure, you may need to slice the silicon with a razor blade to make things easier. Keep doing this until the whole thing comes apart.
Once it is apart, you will see that the entire amber piece inside the lens is a removable section. Carefully pry it out by flexing it inward and releasing the four prongs holding it in. Be careful not to break it, as it will not hold properly if you ever want to put it back in.
This is the tricky part...putting the assembly back together. Carefully align the lens back on the enclosure and get it seated the best you can. The silicon will help keep it in place while you do this. You will notice that since you pried it apart, the black silicon stretched a bit. This will seem like the lens does not fit right. Don't worry, just be patient. Install any spring clips that you can. The ones that don't seem to fit will take some work. What seems to work best is using a pair of needle-nose pliers adjacent to the area where the clip sits to compress the seam. While you are compressing the seam, use another set of hands to get the clip(*) back in place. I would try to make sure that you get them all back in.
Just to be sure, I would spread a small (I mean small) bead of the same type of black silicon (you can pick it up at any auto parts store...I think it is called windshield silicon) around the entire joint of the lens. Let it cure before you try to put it back on the car. Otherwise, the installation is the reverse of the removal.
I would also suggest doing one lense first to see if the effect is really what you want. Plus, please keep in mind that if you really screw it up (break something bad) a new lamp assembly will set you back over two bills and you can't buy the individual pieces/parts that make it up.