ingenious headlight clip replacement -
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Rugged Ridge 8500lb Winch w/ Steel Cable $294.99 Shipped OSmittybilt Products at Oconee Off-Road!Building a Bumper?

Unread 06-13-2014, 02:19 PM   #1
Registered User
1998 ZJ 
Join Date: Apr 2009
Location: Virginia
Posts: 700
ingenious headlight clip replacement

That awful design of the headlights on the round steel adjustor peg, I was able to improve on.

Would not pass due to headamp loose.
Headlamp we bought new and clip broke after a year.
So either buy another headlamp or use hot glue.
Simply just get rid of the dumb defective design that round clip.

1. Unscrew the left side adjuster all the way, remove the stud.
2. Hot glue the ball stud in the round hole of the headlamp plastic. I slightly biased placement towards rear of car.
Make sure the flat of the stud is horizontal! As that is keyed to the adjuster.
Stud still had plenty of adjustment available for alignment of light, so you can just center in the hole of the headlamp ear mount.
Keep lined up straight and reinforce hot glue on both sides of headlamp.
3. Put some gear oil on the stud threads or grease.
4. install headlamp back into the headlight jeep housing, turn adjuster to reengage the threaded adjuster rod with the ball stud glued onto the headlamp.

The hot glue has give so it flexes but is strong to hold headlamp secure.
Pic of the attached stud hot glued into headlamp.

You might be able to do the other ball stud side the same way, if you have room to remove fixed ball stud with headlamp in place.

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