How to Change 94-96 L400 Lens

[dennis_lambert]

Here is a Quick "How to" on Changing L400, 94-96 Lens.
First I Tried to bake L400 Headlights in the oven and wow what a stink...
I had too sleep in the tent trailer that night...
Here is an Alternative Method of removing Non Compliant Headlight Lens..
It Actually worked Amazing!!

1)Remove Retaining Clips and Place Assembly in Barbecue with Lid open and Glass down for about 10 MIN on med heat**Wear Safety Glasses**
Note:Do not place on side place Glass down as plastic housing cant take the Heat..

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Remove Lens once the Existing Sealant becomes Gooey,I used a wood Chisel and Carefully pried it off by slightly twisting.

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Now clean the Housing Channel a bit...Not necessary to get to crazy just get the big chunks out so the new lens fits down.
Note:This Sealant is Difficult to get off so try hard to not get it in interior of Housing.
Note:Caution..The Chrome looking Reflective Surface inside is a coating that can be Easily Damaged by rubbing or using harsh solvents.

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3)Fill Channel about half full with fresh Adhesive sealant,place new lens in and Carfully install retaining clips that hold the lens in place while curing,I put them on with a Dab of Goo so they would not fall off..

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4)After Cured I Masked off the Bond line and fay sealed once more to fill any voids...

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Peel off masking and Voila!!

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And Finally here is Buffalo Neils Finished install of New E coded Headlights
attachment=1]buffolo neil.jpg[/attachment]
Now we have to take care of this faded plastic...
http://nomadjdmautopartsca.ipage.com/index.html

[psilosin]

Now you're cooking with gas!!

[jessef]

Any BBQ sauce ?

[dennis_lambert]

Any BBQ sauce ?

Yep... I Basted it with Bulls Eye!!
Cheers!

[Simon84]

Great tip!
I just did mine and found a good yet long winded video on youtube that helped me figure out how easy it is to get the headlights out.

https://www.youtube.com/watch?v=gNA0JzfCrLs

It also shows you what happens if you bake your headlight pods at 220 centigrade. They melt!

Here's my headlight on the BBQ:



While I was at it I cleaned up the signal light lenses. I used the toothpaste method which I also learned from youtube.

Here's a photo with just one of them done for comparison:



And the lights back on the van:

[Simon84]

One more thing:
I got my lenses from rising sun and they included some adhesive sealant for free. I think its called butyl tape and it worked great!

[macro]

Nice job!