01+ Broken Headlight Adjuster Fix (E39)

hey another E39 owner in DFW, welcome. and those adjusters will probably break again in due time. its just how it works i guess. id try to layer them with something that would support them. maybe JB weld?

email me the PDF:
chivas228 at gmail.com

Chivas:
DIY .pdf on its way to you.

thanks!! i got it... trying to cut it up in 2 so it can be attached as 2 files.

Great find. My adjusters aren't broken yet. I look forward to reading more about your fix.

Now why didn't I think of that? 2 files? If you have any trouble let me know, I can go back in and edit. I did this in PowerPoint.

Chivas:
I made some changes. Hope this helps others. If anyone needs higher resolution pics, just PM me.

Mike

Very nice write up! Thank you a bunch! I will reference these when I get my new adjusters. I HATE driving at night right now.

Do you have oem ae on your headlight?

Yes, original OEM headlights .........

putting this in the FAQ. thanks!!!

Great DIY write up!!!

Few odd questions:

a) where stated in write up, "thread the new pieces on the existing headlight adjustment white screw", is the cutting of the new threads necessary on the new piece done by the screw with the 10mm nut (that can also be turned by the white adjuster screw but not advised), at the direction shown in following picture?



Or, maybe i got this thing all wrong in how the new adjuster piece is screwed/threaded on to the existing screw.

b) In the following picture, how are the A and B adjustments affect the proper alignment of the headlight?



c) After cutting the new threads on the new pieces, is it recommended to still use the 10mm nut to do final headlight adjustment? Or use the white adjuster screw?

Thanks much!

Damnit if only I got balls to open up my headlight! Anyone in the bay want to do mine? :angel:

Gixxer:
Question = a) where stated in write up, "thread the new pieces on the existing headlight adjustment white screw", is the cutting of the new threads necessary on the new piece done by the screw with the 10mm nut (that can also be turned by the white adjuster screw but not advised), at the direction shown in following picture?

Answer = correct. I turned the 10mm black nut clockwise(below the white adjuster knob) to thread the new piece on the threaded rod inside the chassis. The new piece did not look like it was threaded, and it required some torque to run all the way up to the end. Do not use the white knob to do this, the teeth cannot take the stress. Once you have run the piece back and forth a few times, the white knob will handle all future adjustments.

Question = b) In the following picture, how are the A and B adjustments affect the proper alignment of the headlight?

Answer = (A) seems to be the main adjustment for height. I think (B) is for the high beam as it did not seem effect the low beam pattern. I never had the high beams on when I set the lows, so I am not sure. I could not find any info in the owners manual on headlight adjustment procedures. Maybe someone else will chime in with additional info.

This may sound stupid but how do you know if this repair is needed. I just received my 01 530 with HID and it seems to be point straigth down, i turned the screw at least 5-8 rotations with no noticable difference on the wall. I am wondering if my is busted also.

This may be a little off the subject but I have 1 in 3 people flash their high beams at me even though just my low beams are on. I have the auto leveling HIDs and am wondering if thats normal or could they be adjusted too high? Any input would be greatly appreciated, especially by wife.

i have another sorta off topic Q...

if you have say a 99 like i do, do you have to follow the same steps to change the adjuster? or is their another way for the older model non-angel eye style headlights?

thanks

Crazy Glue Works Great Also!

Good write up. One thing to note is that not all OE AE Headlights will come apart in the oven or with a heat gun, some are sealed with epoxy and will not pry apart.

For example my drivers side comes apart real easy in the oven, but the pass side has will not come apart.