pulling the headlight cluster

[rusted]

91 DX

One headlight cluster leaks -- it gets fogged inside.

The inspector does not like that. I think I have it dried out enough to pass now, but I'd like to pull the cluster and reglue the lens-reflector seal.

But it looks as if I must first pull the top bumper trim piece in order to get enough clearance to remove the cluster. Is this correct?

I see 5 vertical Phillips-head screws, 1 at each end and three in the middle.

Do they in fact hold the trim in place, and are they machine screws? (All are rusted solid and may require Extreme Measures to get them out.)

Suggestions?

[BullShifter]

You gotta take off the front bumper - there are 4 bolts holding the headlight(2 top - 2 bottom) Removing the bumper is simple - 8 bolts/screws.
http://www.binghamtonlife.com/manual...s/91-20-55.jpg
http://www.binghamtonlife.com/manual.../91-23-123.jpg

[ci5ic]

Yep. Gotta remove the bumper.

It's possible to do it without removing the bumper, with a wrench extension or two, but it's a pain in the ass to get that one bottom bolt out, and even if you do get it, it's an even bigger pain in the ass to put the bolt back in when you're done.

[rusted]

Originally Posted by jackasssi

Removing the bumper is simple - 8 bolts/screws.
http://www.binghamtonlife.com/manual...s/91-20-55.jpg
http://www.binghamtonlife.com/manual.../91-23-123.jpg

Thanks; I got it past inspection without such extreme measures -- a few minutes with an air hose got 99% of the H2O out.

But a bigger thanks for the on-line manual reference; I was about to ask where to purchase a shop manual....

[BullShifter]

www.helminc.com for a paper version - there are a few parts missing from that online manual.