Thanks to B.C. and Goldy for tips on rebuilding a headlight housing assembly, as it turned out I needed it!

I found all three of the housing bolts, 2 out of 3 of them didn't come loose and just spun (I guess I needed to use PB Blaster every night for days prior to trying these!). So I went out and bought the new nuts and bolts needed and I took a plastic pen and took the innards out to use the plastic tube as a bolt head extender as in B.C.s tip avoiding epoxying new bolts in.

when I removed the housing and attempted to disassemble the bucket from it I broke 2 of the 3 adjuster molds (one with the spring clips holding the adjuster screws into the plastic molds). I super glued the one that didn't have a spring clip and used the "fiberglass matting and resin" idea from goldy to mold myself a replacement molded retainer for the clip, a hack saw and a drill was all that was needed to replicate the holder.

All in all I have a much clearer headlight now (after trying oven cleaner I went with the wet sanding method - 600 grit sand paper and then some plastic polish). And a much better silicone seal on the lens which should keep out moisture in the future.

lost the nut for the one housing bolt that didn't break, spent far too much time but learned a lot about fiberglass and plastic, also must have busted the connector to my parking/turn signal bulbs because they are not working now (that connector was a pain to disconnect!)

but I got the job done, not as good as a new set of e-codes but not as expensive either!

thanks to all who helped me with tips to see this thing through!

jack
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Bad Blue, '86 245, 250,000 mi., Columbus, Ohio

The wiring connector is a small PITA, getting the PS ground wire is a large PITA. When you get the PS and DS ground wires off, cut the wires about midway, and put in a spade connector, male and female, crimped in. Makes removal next time a relative breeze.

BTW, while the whole unit is out (if you have time) it's a good time to disassemble the marker light section and use silver spray paint to brighten up the reflectors behind those weak little bulbs. This can be done on the car, but there's always the chance of a wandering drop of paint.

Good Luck,

Bob

PS Glad to hear that the "system" worked.

Not familiar with "PS" and "DS" acronyms for the ground wires.... the ground wire that ran from the connector to the fuse block was a philips screw and was no problem to remove.

It looks like the problem is loose bulb fittings in the marker light section. I sprayed some circuit cleaner/lube in there and it helped me get a good enough connection but I may have to do some tweaking in there to try to tighten up those bulb connectors... too bad I didn't think of that when the whole assembly was out!

anyway thanks,

jack
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Bad Blue, '86 245, 250,000 mi., Columbus, Ohio

I used them in this case since RH and LF depend on one's vantage point. I found the PS ground wire anchor to be behind the washer fluid tank. After half removing the tank and removing the ground wire, I put in the disconnect, so as to avoid that little drill when next the hadlight needed removal.

Regards,

Bob

:>)

It all makes perfect sense now!

since I was just working on the DS I didn't know if I was missing something that I should be careful about

thanks for the education!

jack
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Bad Blue, '86 245, 250,000 mi., Columbus, Ohio