DIY: 2000-2004 Headlight Bulb Replacement

[triangleman]

Okay, I know this is actually pretty elementary and easy, but I figure having a few pics could help some people out. This stuff is actually located in your owner's manual, but in case you can't find it, the procedure's pretty easy all around. Bottom line: under no circumstances should you pay your dealer to do this. It's easy.

You will need:

- Size ten (10) hex socket wrench for the inside bolts.
- Large Phillips head screwdriver for the top bolts.
- (Optional) Some needle nose pliers to work on the contacts.

Okay, so here's our patient. The manual makes it look like you can just unscrew the little white caps on the backs of the headlights and swap them out. I'm not sure what they were thinking, because it's darn near impossible to joggle the stupid things free.




Ignore it and just take the things out. This is where your socket wrench and Phillips head come into play - a reminder, there are two hex bolts and one Phillips head bolt per light.




Much better. Now we can have some space to work. Underneath that white cap lie your headlight bulbs - both low and high beams.



The black connector (or in my case, the faded grayish connector) is the one you want to unplug. No big deal, just pull it off.

After that, gently work the spring free from underneath its hook.



It is quite important that you don't touch the bulbs with your fingers while installing them. Hold them by the metal, or use a paper towel or something. The oils on your skin can create hot spots on the bulb which can lead to premature failure. Which kinda sucks if you've paid like thirty bucks for a nice pair of headlights.

Optional: While you have the contact out, you can use a pair of needlenose pliers to gently squeeze them together (if your contact is feeling a bit loose and liable to slide off the back of the bulb). Take care, though - the plastic sheath is brittle and (in my case) cracked a little bit. No harm done overall, though, and it fits much more nicely now.

After that, simply work the steps in reverse:

- Lower the spring back down and underneath its hook.
- Replace the contact.
- Replace the white bulb cover.
- Reattach the headlight.
- Present middle finger in direction of overcharging dealership.
- Celebratory brewski! (It's actually a Sam Adams Oktoberfest. :P)






Cheers!

[AWDFTW]

Huh. I just took the battery out to save on the skinned knuckle factor. Didn't have to do anything else.

Had both of my lows burn out last summer. Haven't replaced the highs yet.

[wilsonhp]

Be REALLY REALLY careful with the spring lever that retains the bulb. It's located with a little plastic pin, and held down with a little metal plate with a single small screw.

That little plastic pin will break off in a heartbeat if you even look at it funny. And it's molded into the main plastic piece. Not replaceable.

Ask me how I know this.......... (and even on a brand new headlight assembly !!! )

[H61]

I just had a low beam on my 01 H6 go out. It only lasted 171k…..lame, should have lasted a little longer. Haha. That was the first bulb on the entire car to go out. Picked up a 7.00 stock Sylvania bulb from AutoZone. I was going to upgrade to Sylvania Silverstars but reluctant because too many say they do not last long. As far as the OP removing the lens, in my case on my H6 there was plenty of room and no reason to remove anything. Just gently twist the inner bulb housing and pull it away from the lens. Plenty of room to remove and replace bulb. I did the air cleaner side but the battery side looked to have plenty of room as well. Worse case on the battery side would be to remove the battery.

[srpuywa]

I removed the headlight - it was way easier this way - thanks for the write up

[1 Lucky Texan]

what holds that white cap in place? friction?

[Brucey]

I've replaced both low beams in my car now. Neither required removal of the headlight assembly.

The white cap twists off and on. I did both in the parking lot outside the store I bought the headlight in. One was while on a road trip in the middle of nowhere, Kansas.

[AWDFTW]

A quarter turn or so.

[H61]

Originally Posted by srpuywa

I removed the headlight - it was way easier this way - thanks for the write up

How is it “way easier” to remove the entire lens than to give the rear lens assembly a ¼ twist, remove and replace bulb? Took me less than 3 min. I never removed the entire lens but I can not imagine it takes less time than that. Either way, glad it worked out for you.

[Euchre]

I think it depends on how large your hands are, how thick your arms are, and how flexible and nimble you are. When I did my high beams, I pulled the intake snorkel to make the one side easier. One of my 'buckets' was much harder to get loose than the other as well. One of the bulbs I pulled was also bent at the base - so somebody was bit rough on the 'fast, easy change' of the bulb.