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Discussion summary
YOUR RESEARCHReplace headlight clamping bow. 996.2 C4S
Reported or suspected cause
rounding of the aluminium 'key'
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Reported cause
Wynne, are you sure that the hex end of the bow is the problem, for me it turned out to be the rounding of the aluminium 'key' that Porsche supply for turning it.
Leading evidence: 'rounding of the aluminium 'key'' (1 discussions report identifying this cause; no attributable repair resolution). Across 1 matching discussions, the most frequently mentioned possible cause is 'rounding of the aluminium 'key'' (1 discussions; 1 report identifying it and 0 suggest it). The most frequently discussed action is 'Replace bow' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Suggestion · Original poster
I've got my headlight out for new bulbs but the hex end on the clamping bow is goosed so I want to replace the bow.
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Suggestion
Ive recently done just this along with replacing the whole headlight trays.
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rounding of the aluminium 'key'
No successful repair reported for this finding.
1
Identified cause
0
Suspected cause
0
Reported fixes
Read evidence and context
Discussions that report identifying a cause
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Reported cause
Wynne, are you sure that the hex end of the bow is the problem, for me it turned out to be the rounding of the aluminium 'key' that Porsche supply for turning it.
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
9 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
911uk: 1 discussions
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Surprised search doesn't find an answer. I've got my headlight out for new bulbs but the hex end on the clamping bow is goosed so I want to replace the bow. Available to buy with bush and split washer.
BUT I must be a total idiot because after removing the split washer and releasing the three tray nuts I can't see how to get the old bar out.
Any help gratefully received.
Wynne
C4S [ OIG 9960 ] :?:
I had the same sort of problem about six months ago... and I got them out, so it can't be that difficult!
From memory, once you have removed the circlip, the only thing that is holding them in, is the little white bush/collar .. and if the bow is corroded it might not want to slip though it to enable you to manoevre the bow out. Does that make any sense?
If it doesn't i will have a look at my actual set this evening
Exactly....i'll clean up the bit of corrosion and try again. Nice to know I'm not missing anything.
Thank you Hughb....don't disturb your car for me.
Wynne
Ive recently done just this along with replacing the whole headlight trays.
With the circlip out you slide the rod back and out the bottom, theres a 90 / 180 degree turn at one point to get past the first bend in the rod.
It should slide in and out of the bush easily so if thats not happening it may need some persuasion.
Once it starts sliding it should be pretty obvious what contortion is required
I think we've cracked it.
Its the pesky little bush that is the problem, or rather the corrosion inside it.
Wynne, are you sure that the hex end of the bow is the problem, for me it turned out to be the rounding of the aluminium 'key' that Porsche supply for turning it. As soon as it encounters a bit of stiffness it's the aluminum tube that gets rounded. I have just substituted a steel socket plus driver for this job. Aluminium is just not the right material for this 'key'.
Sorted
Thank you, great that people are happy to share their knowledge.
Its sorted.
Yes the hex end definitely rounded and conical. A couple of goes turning with a 4.5mm socket left only....so new one needed.
I agree the Porsche 5mm socket bar is not ideal as it can round off inside. A proper 5mm socket on a little extension is so much better. When the bar is not being gripped by a 5mm socket I found a 4.5mm one was good enough to get it to turn and get the headlight out.
As described....
a) remove surclip
b) clean up the bar at that end so that the white plastic bush slides back along the bar.
c) rotate bar until the cranked end is pointing down
d) slide towards the frunk so that the clank drops into the hole underneath that end that wasn't visible under it.
e) lift up the cranked end and slide other end back out of the bush end.
Not obvious.
Thanks again for your help.
Wynne
Just done the same and the part numbers and prices from Porsche UK are:
Locking Lever - 996 631 273 00 - £20.10
Lock washer - 900 116 004 09 - £2.29
The Lock washer is an E-Clip and is 11mm diameter, and 4mm inner diameter so I think any 4mm E-Clip circlip will do the same - lots on eBay for not a lot
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