I bought some 2006 headlights and im getting ready to ship them to MR.zipps to get painted. I cant figure out how to get most of the stuff of the headlight I.E. wire harness, and the stuff inside the headlight. Does anyone know a good place with pictures to show how to remove all this stuff? I found some DIY for painting headlights but they didnt describe real well how to remove stuff before painting.

 

I would imagine Mr. Zipps will remove the ballast and bulb before he bakes and paints them.

As long as you aren't shipping the turn signals and main ballast harness I think you should be alright just sending him the entire headlight assembly. Might want to shoot him over an email.

 

this is what he said in his email.

"you need to remove all the bulbs, ballast and wiring harness. Just send the headlights casing."

I removed the turn signal bulb, i cant figure out how to take the wire harness of cuz it seems like the main grey connector is glued on or something. Im not real sure what part the ballast is, is that the whole HID bulb assembly inside? If so how do you get that out?

 

Not sure if you were talking about my instruction but let me try.

1) Remove every bulbs.
2) The ballast is located under the headlights ( I think it was gray). You will need a phillip screwdriver to remove it.
3) With all screws removed, there should be a brown blug into the ballast remove that.
4) All the wires, you just need to pull it all out. The end part (the brown end that was plug into the ballast) just use a screw driver to push it out and pull it out from the other end.

I hope that was helpful enough. I done so many headlights and scary how I remember this hahaha. Need some more help, post some pics and I will try my best to help you.

~Robert

 

im stuck on that brown plug. I unplugged it but there is a shiny metal piece that holds it against the ballast (grey square) it has a screw on it and that screw must be torqued down hard cuz it doesnt move and im afraid if i try any more i will strip the screw. I will post up pics in a sec my batteries are charging for my camera.

 

oh yeah I remember that tiny screw. Yeah it is quite torque down. I would just advised that you removed that very carefully. Lucky I got some quality screw drivers that doesn't strip screws as much.

~Robert

 

i dont think its my screwdriver. I dont know what to do. It wont budge a bit. I can get it out without removing that screw and pulling the wiring with the brown plug out of the headlight.

 

when you get the chance, post some pics so I can see where you are.

~Robert

 

Here is the screw that wont budge.



Here is a pic of what i need to get done and what hasnt been done red is needs to be done and green is already done.


and here is a pic of where i think the wire harness comes off at? I have no idea though. Help with the wire harness please anyone im trying to mail these off tommorow.

 

Sweet, you were right, i changed to a nicer screwdriver and it came right off. I guess the screwdriver i was using didnt fit to well into the screw. So the grey ballast box is off with its wire and HID bulb and bulb holder. Now all is left is the wire harness all together.

 

~Robert

 

cool glad that I was able to help. don't forget to remove your bulbs before shipping. Any questions, let me know.

~Robert

 

when you said pull down which way do you mean. Are you talking about the grey connector thats circled? Thats the only way i can see the wires coming off. Ive pulled on the grey thing every which way and it doesnt seem to come off.


I got the screw off by the way i just went to a better screwdriver like u said.

 

well doesnt he want the whole wire harness off? or just the bulbs? I posted what mr.zipps said in the third reply on this thread.

 

That screw is a bastard.

The harness plug just takes some leverage. When you pull it off you'll see that it's just held on with a little tab that clicks into place. You could probably find something to wedge in there to unlock it, but it's pretty slim. Get a bigger screwdriver and lever it off. It'll come.

 

cool ill try it im just scared to break these $900 headlights haha.

 

He does want the whole harness off. He's baking the headlights (and the chances of electronics failing when you get the lights back is not something he wants to deal with.) which means that sweet potted Matsushita Gen 3 ballast will release some of that silicone and make an unholy mess. Not to mention the wiring, electrical tape or the covers around the wires. Not terribly difficult honestly.

I can't wait to get my car back on saturday to start on that next set of headlights...

 

Yup, that is the way to go.

~Robert

 

honestly i will be lost when i get my headlights back and im trying to put them back together. It will prolly be two weeks from now and i wont remember how this stuff goes back on haha. i guess we will see.

Im still trying to pry that connector off with the wires on it. Its not budging i even am using some thing to push on the tab inside the connector

 

Is this where you guys are talking about? That Tab that is circled in red?
and which way am i suppose to pull on it green or blue?