How to remove 1991 Headlight Assembly?

[Manarius]

I'm trying to fix the all too common yellowing headlights problem, but I can't get the headlight assembly out. Are there any hints?

[sheepdog]

WD-40, Ratchet set, big hammer. I dont have a gen1 so I dont know bolt locations, if thats what your looking for I guess my comment wasnt really that helpful....

[Manarius]

Well, I got the headlights out...but I went to lowes to find 2000 grit sandpaper and the highest they had was 320....I sanded a small spot and it made more scratches then you're supposed to have...

[Tris_STi]

There's about 4 bolts, although it's hard to picture it in my mind.. haven't done this in awhile. HOWEVER, I have the solution to your problem, so don't listen these 2nd gen elitists. . .

There's bolts on the upper and lower of each side of the headlight. Follow the plastic mounting portion, and there should be a M12mm (?) bolt that undoes this. The 91s have leveling springs that are also attached, so once you undo those bolts, don't be surprised if it doesn't pop free. You'll need to unhinge those springs first, and THEN pull the light assembly out. You've taken the corner lights out, right? Good.

Okay, on to the yellowing.

You'll need:

- Elbow grease

-#0000 Steel wool

-Something to wetsand with --water is good, so is WD-40, or most cleaner waxes. I used maguires, or Zymol, both are excellent. You'll really need to scrub, but these things SPARKLE when they're finally clean. Trust me.

-Clear Coat. I recommend NAPA 303 UV rated clear coat, as it's top-of-the-line, and will fully prevent the yellowing from coming back. (it's UV damage to the lense, that's all)
Other clear coats look/will do fine, but you'll definitely want to seal up all the work you just put in, otherwise the yellow WILL come back.

Once you've got the lights off, and the bulbs out, take 'em to your bench, table, whatever, and start wet-sanding! It works if you're drunk, or high, that way it doesn't seem so tedious, and you'll put down more hand-pressure than you're aware of. At least I did. :lol:

It's a really easy and quite effective operation to perform, just make sure you reattach all those bolts and springs again. Although it's not crucial for the springs to be back in there, I'd double-check that the lights are mounted tightly... Other motorists hate it when you go over bumps and your headlights 'bounce', making it look like you're flashing your brights.

Good luck, and take pics of the before and after, I'd love to see how it turns out!

[Disturbed_beast]

What no pictures we like pictures well at least i do

[Wiscon_Mark]

Here's pictures to calm the beast :D
Before:
https://sl-i.net/FORUM/images/imported/2005/07/HeadlightD-1.jpg
After:
https://sl-i.net/FORUM/images/imported/2005/07/HeadlightDNEW-1.jpg

I used:

400 grit (wet)
600 grit (wet)
1500 grit (wet)
a buffer (dremel tool, use a light fluffy buffer, not a compressed buffer)
waxed it
more buffering
they sell assorment packs of sandpaper at walmart that should have high enough grit. I don't really like the idea of steel wool, but I don't think Tristan is trying to sabotage your headlights, so....try either one :D