headlight hell

Hey, I did a quick search, but didn't really find too much.

My housemate has a 96 JGC, both headlight bulbs burned out in the last 2 weeks, (no its not hte switch, both bulbs burned out seperately). So we got replacement bulbs, and started the process of replacing them. Got the old bulbs out, but we simply cannot get the new bulbs back into the assembly and retighten that plastic gray twist-lock POS.

We worked on the first one forever, one of us getting it into place, the other trying to hammer it clockwise(tight) with the tip of a flathead screwdriver. We tried everything and simply cannot twist these plastic gray things back on by hand. So after an hour, we finally suceed in getting it tightened with the screwdriver (so we think).

We take out the battery, and start on the 2nd bulb. We get it out, and start to put it back together with the new bulb. Try and try and try, we keep getting the gray thing to lock up crooked. And we keep loosening it again and trying it again and again. Well the sun had gone down and it was 5 degrees outside by this point, so we can't even feel our fingers. And we hear something snap. Sounded like the bulb broke, but it didn't, some plastic housing part broke, we can't see it with a flashlight, but the whole head light assembly moves alot more freely, so something definantly broke.

So we look back to the first one, trying to compare and figure out what we broke...and we notice that the gray POS fastener has since come loose(we have no idea how) AGAIN. SO we gave up for the night, as it is way too cold, and we were WAY too frustrated. I'd assume someone else has dealt with these same POS gray plastic twist-fastener things. Were they hell for you? Any ideas/ tips, because we are out of ideas, and need to get them working by tomorrow evening.

I know they are an ugly thing to change - especially the passenger side with the battery needing to be removed and all. The drivers side is not too bad if you take the air box out as well.

It did take a LOT of patience changing mine in a warm garage and I can just imagine doing it out in the cold like you are.

They do line up eventually.

My sympathies!!!!!!!!!!!!!!

JD

The snap may have been the adjustment screw attatchment point. I am pretty sure it's a ball and socket joint, like in the side mirrors. you may be lucky and just have popped the ball out of the socket. When I got my 94 zj, this had happened to the Drivers side headlight. I couldn't focus the beam right until i figured this out. it wobbled visibly if the engine ran rough. check, it might just be this.

That's odd that you had problems. I changed both lights out to aftermarket lights and finished in about 15 minutes. I had to take out the battery and I have a different air filter intake (without the box). Are you sure they were the right bulb replacements? (no I'm not saying your dumb either)I agree that it was probably your alignment tab that snapped. That's what holds the light assembly secure too.

I was cleaning the engine today, and you arent kidding that its hard to change the lights. I guess it might be easyer to change the passenger side since you just remove the battery. But I dont know what to do about the air box. I dont want to screw with that, so when it comes time to change bulbs, I dont know what I'll do...

Well to fasten the headlight housing back to how it was all you have to do is add some pressure when putting the fasteners back in place. When turning it you are going to feel when it clicks back to its place. Since I have a K&N FIPK kit theres alot of space so its easy to change when they burn out. And yeah I do move the battery just a bit.

Well I replaced my bulbs awhile back with some Sylvania SilverStars. It was a bit of work but I didn't have near as many problems as it sounds like your having.

You have to push in on the holddown clip (grey part, it has an O-Ring on it to seal the headlight assembly from Water/moisture) this O-Ringis whats making it difficult, just be patient like JD said. it will all go together like it should.