Has anyone ever had problems with the mounting bolts ( 8mm ) for the headlight assembly? One of the two on my '99 appeared to come loose, but it will not tighten up. I am assuming it came loose, and with the vibration and all, probably stripped out the housing threads. Any Ideas?

I had purchased the 4-year extendo warranty from the dealer, but they want to charge me $286.00 to replace the headlight assembly, stating it is "not a warranty covered item". What a crock-O-crap...

I would understand if I wrecked it or something and it was definately my fault, but this is an obvious defect of some kind.

Any suggestions??? Thanks!!!

 

yea, i know the problem i had the same thing a on 99 ex that i bought used, when i noticed the light lose i tried to tighten it up then noticed that the plastic under the light which holds the bolt i place was cracked allowing the nut to free spin when i tried to tighten it. i made a custom bracket and screwed to the fenders and the light assemble. it worked and was better then spending alomost $300.00 on a new one.


hope i helped you out

quad040

 

As mentioned before you can make a custom bracket, or what I did was fill the holes with a silicone caulk which will help with the vibration. They haven't fell out yet and its been a year or so. Just a suggestion!

99' 400ex Born and bread to rip and shread!
Craptor Eater

 

I had the 2 bolts lose and it turns my bracket busted. I lost low beam because they shook around so much. I took of my front plastic, replaced the headlights, and put a lot of silicone around the bracket. It works! just let the silicone cure.

 

mine were busted too, I removed the plastics and hot glued around the housing in the back, it worked excellant!