04-05 Clear Headlight Mod

Subaru DIY modifications that you can attempt one your own.

Moderator: BOOST3DWRX

04-05 Clear Headlight Mod

Postby BOOST3DWRX » Mon Dec 03, 2007 5:50 pm

*I am not responsible for damage to you or your car or oven. Attempt this mod at your own risk! I am also not responsible for a voided warranty.*

Well I have read a bunch of these over the past years and this is sort of a compilation of all the ones that I have read.

What you need:
10mm socket
Phillips Screwdriver
Flathead Screwdriver Small one
A Trim Pick, I have a Nylon one a Flathead covered in tape will work as well
Oven, Oven Mits and a Pan
A friend could help

First off you have to remove your Grille. There are 4 clips up top be careful that you do not loose these. There are also two clips underneath that hold the grille from the bottom side. This is what I use the Trim Pick to get at you can also use a flathead with some tape on it. There are two slots on the upper part of the grille that you can stick your screwdriver down in to pop these out. Use a flashlight to look behind the grille if you can't see what im talking about.

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Now that the grille is out you have access to the one of the three bolts that holds the headlight on. Use your racket to get this bolt out:

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Now for the upper two bolts on the top of the car:

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Now the headlight is loose and you will be able to POP it out. There is a clip that hold it on and two pegs towards the fender of the car.

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The pegs:
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Now that you have the headlight out of the car you can start to take it apart. Just be careful what you set the headlight down on you don't want to scratch the lenses.

Remove the white tab there are two screws that hold it on. and remove all the bulbs and harnesses.

There are also screws that hold the headlight to the lenses remove all of these also there is one hidden behind the piece of felt.

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Pop it in the over on a pan for 9-12 minutes at 200 degrees to soften all the sealer on the headlight.

Now use your friend to help you pull the headlight apart. Make sure that you do not let any of the sealer get on the inside of the headlight. Have you friend collect the extra we used a pen to just cut/rip though it.

here is what you are left with after you pull the headlight apart there is one screw that you need to take out in order to separate the center part from the lenses:

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Remove the orange markers the first one is just a pop tab:

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The side marker needs a screwdriver:

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then there is the little bubble for the running lights you can leave this if you want, I wanted to take it out:

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Now you have to put everything back together and pop the headlight back in the oven to melt the sealer again. Some writeups call for adding more sealer I didn't need any and I have had mine cleared for over a year with no leaks. 9-12 minutes at 200 degrees should work well. Now once the headlight is out push it together hard. Now replace the screws this will help to pull the unit together more.

And the finished product:

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Repeat this process to the other headlight and then reverse the steps up top to put them back in the car.

Enjoy.
Rice King
BOOST3DWRX
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