How to remove 06+ headlights and dissasembly for paint or clear corners - Subaru Forester Owners Forum
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post #1 of 47 (permalink) Old 12-27-2006, 02:52 PM Thread Starter
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How to remove 06+ headlights and dissasembly for paint or clear corners

Some asked that i photograph my experience. I painted the bezels in my 07 FXT headlights. Here's what you gotta do to get those pesky headlights out and separated to modify internals.

Step 1. Disconnect battery.
Step 2. Remove the bumper.





There are a series of snap fasteners as seen in the photo. There is one in each wheel well behind the inner fender cover. Its right near the crease.
There are also snap fasteners holding the plastic protector cover on to the bumper. Gotta remove those too.
Also remove the snap fasteners on top by the grille



There are seams with clips on the bumper. You have to be careful removing the bumper so not to break the perforation on the seam, so that it can go back on.

Step 3. Remove airbox elbow


Step 4. Remove headlights
Disconnect the 3 connectors. There are 2 in the corner of the unit by the amber light. The disconnect the low beam connector. The different style high beam connector is wired through the low beam connecter therefore does not need to be disconnected.



There are 4 bolts holding each assembly in place.
there are 2 on the inner side of assembly.

There is an obvious bolt on top of the light. And the 4th is on the outer side that would normally be covered by the bumper.

You must also remove a phillips screw close to the hidden bolt. You cant miss it. Also, in that area there is a white square snap thing. You must push in the 2 prongs on it then the light assembly should come free.

The arrow on the left is the 4th bolt location. The arrow on the right is the white plastic snap. For reference, this is on the sides of the car. not the front.

Once you have the light removed you can dissaseble it as follows.
Step 1. Heat up the epoxy sealing the light together. You can do this one of two ways. I recommend using an electric heat gun.
Or you can bake your light in the oven. I will not provide those directions and i wont be held liable if you melt your headlights. Just use the heatgun around the seal

Gently use a flat head screw driver to unsnap the snaps all along the housing. You may need to use the heat gun again to warm up areas that you missed. This process should take less than 5 minutes.




Then after you have separated the front from the back, remove the 5 screws holding the parking lamp piece and the bezel in place.

Then you can easily remove the amber reflector if that is your project. But if you want to paint your bezel, then keep reading.

To look like the forester Sti, this isyour inexpensive alternative to have the "look" JDM headlights go for as much as 1500+ USD.

So, tape up the bezel like so. The only thing that should be taped is the rings around the light holes. The bottom surface and the 2 wedges between the highs and the lows should all be untaped. Be very careful. This is a very detailed task.




Then when you have the tape the way you like, paint em. I personally used 1 coat primer, 3 coats base (gloss black), 2 coats clear (crystal clear acrylic).

The tough part of the whole project is taking the tape off. This is where all your hard work goes down the drain. A recommendation might be to use an exacto knife and go around all the edges of the tape. What happens is when you peel the tape up, the paint edges come with it.

After you have done what you came for, assembly is a 30 minute job.

Simply put the bezel face down and the park lamp piece and put the 5 screws back in.

Then put the assembly back together, and make sure you press firmly and then use your heat gun and re-heat the epoxy. You may wish to remove all the old epoxy and put new epoxy in there. Might be a good choice.

Once the housing is all back together, hook up your connectors, and slide it back in place. That little white box clip will need to be engaged and then it will support your housing while you bolt it in. Then put the bumper back on.



Dont forget to install the airbox elbow and the battery connection

See, that wasnt so hard. Enjoy.



The total time for me to figure out and do it on my own was about 5 hours.

Thanks to Jerry from Continental Subaru and Ben from Hodges Subaru for the PDF files.

I welcome your comments and experiences.


*(MikeyMike)* 2007 Forester XT

Last edited by MikeyMike; 12-27-2006 at 05:00 PM.
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post #2 of 47 (permalink) Old 12-27-2006, 04:38 PM
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Looks good, now do the taillamps


It's real velour. Just let yourself go!
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post #3 of 47 (permalink) Old 12-27-2006, 04:55 PM Thread Starter
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I was thinkin about that. But i am just gonna buy them.

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post #4 of 47 (permalink) Old 12-27-2006, 05:50 PM
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Give it a shot, what's the worse thing that can happen? You have to buy new genuine STi taillights.


-Ben


Edit:

I found a set of 06 taillights for cheap locally, maybe I'll buy those and mod them, or swap with someone for 06 lights.

It's real velour. Just let yourself go!

Last edited by Hondaslayer; 12-27-2006 at 05:57 PM.
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post #5 of 47 (permalink) Old 12-27-2006, 08:28 PM Thread Starter
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Yea i guess. Maybe a project for next week.

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post #6 of 47 (permalink) Old 12-27-2006, 09:12 PM
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Question

Mikey,

Is that just a 'regular' Subaru hood deflector or specifically for the Turbo model? I was told a couple times (both from SOA & Subaru Canada) that one should not put the deflector on because it could interfere with the the proper air flow into the hood scoop?

But I do like the look of it.

Bren

Proud owners of a 03 XS & 2005 Lexus ES330
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post #7 of 47 (permalink) Old 12-27-2006, 09:51 PM Thread Starter
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I asked the same question when i bought it. I am removing soon. Just leaving it on for the winter so i keep the rock chips on the hood to a minimum. The car was either sent with it on there from the factory, or My subaru put it on there.

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post #8 of 47 (permalink) Old 12-28-2006, 04:16 AM
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Is there any room behind the "eyebrow" above the lights? I was thinking of putting a strip of LED's there so I can leave the headlights off during the day but still have some lights facing forward.
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post #9 of 47 (permalink) Old 12-28-2006, 07:59 AM Thread Starter
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The "eyebrow" is a triangular piece, not only length wise, but depth too. It separates as you may see from the bezel. You can remove the eyebrow if you wish. That piece is also sealed, i dont think you could open it without breaking it. I hope that answers your question. I guess you could say the eyebrow is a light housing. a little white bulb plugs into it.
I dunno, im trying to find the best way to describe it.

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post #10 of 47 (permalink) Old 12-28-2006, 08:05 AM Thread Starter
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Quote:
Originally Posted by shookwell View Post
Is there any room behind the "eyebrow" above the lights? I was thinking of putting a strip of LED's there so I can leave the headlights off during the day but still have some lights facing forward.
Here is what room you have. I suppose you could dyke off that light bulb that goes to the eyebrow, and use its electric source for your LED. This photo shows the location of the bulb, and what kind of room you have in the housing where the eybrow fits. Hope that helps more.



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post #11 of 47 (permalink) Old 06-28-2008, 03:06 PM
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for as long as you had your SG, have you had any leaks?

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- my second SG6

Last edited by tallazzPilipino; 06-28-2008 at 04:09 PM.
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post #12 of 47 (permalink) Old 06-28-2008, 05:06 PM
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Quote:
Originally Posted by tallazzFilipino View Post
for as long as you had your SG, have you had any leaks?
I've done mine twice, the second time was about 1yr. ago. My lights have been starting to fog over the past 2 months or so. I will be re-opening them to clear the fog and then reseal them GOOOD this time. I kind of did it quick last time, not smart.

But I think if I hadn't done it the second time, I'd be fine. As long as you have a solid seal, you're golden.

Drew

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post #13 of 47 (permalink) Old 06-28-2008, 05:08 PM
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Has anyone done this to a SF??

If not, even if so, you should do it!!

Thanks again to MikeyMike (although he's not on the boards anylonger) for a sick write-up. I used this and I know a TON of others used it as well, so kudos to MikeyMike!!!!

H2O GO!!!

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post #14 of 47 (permalink) Old 06-28-2008, 09:00 PM
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THANKS PLEIAD!!!!!

This thread is now in the DIY section!

H2O GO!!!

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post #15 of 47 (permalink) Old 06-28-2008, 10:03 PM
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Quote:
Originally Posted by subisan View Post
Has anyone done this to a SF??

If not, even if so, you should do it!!

Thanks again to MikeyMike (although he's not on the boards anylonger) for a sick write-up. I used this and I know a TON of others used it as well, so kudos to MikeyMike!!!!
leaks and especially fogging was something i was especially worried about.

o, and what i wanted to do with my SF lights was what the green one had here:


SF5 corner light interchange?

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