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 connector 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 dissemble 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 is your 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.
Don't forget to install the airbox elbow and the battery connection
See, that wasn't 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.
► Edit - moderator's note - the images on this write up have been saved to the forum server.