Headlight assembly fix – jeepforum.com electricity and magnetism review sheet

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Thanks very much to Jeepster2k3 for this posting. I recently purchased a preowned 2014 Unlimited Rubicon X and found 4 out of 6 jaw areas on the 2 headlight mounting rings were busted out. In addition to the adjustment posts which I fixed exactly as described above, I also had to repair two of the non-adjustable posts on one side.

I used a variation of the same procedure. I first picked up a 2 ½ inch long #10-24 “Hanger Bolt” which is a bolt with threads on each in: machine threads on one end, and course “wood” threads on the other end. The wood threads were different than on the metric OEM posts, but they are the same diameter so had no problem screwing into the plastic base. Additionally, I used a #10-24 cap nut to create a temporary hex head so that I could screw the hanger bolts into the plastic base using a ⅜ inch socket wrench.

I used JB Kwik Weld which sets up in 6 minutes and withstands 230 degree F to glue 3/16 inch x 1 inch diameter washers on the back of the broken plastic headlight mounting ring. And again, I used #10-24 Nylon Lock Nuts on front and back to hold everything in place. I also used two washers in front #10 washer and a slightly larger ¼ inch washer.

My Jeep has a 3 inch lift and I’m running 35” Toyo MTs with 28 psi so that the distance from the ground to the top of the light beam near the headlights was at 44 inches. To set the proper angle, I parked 25 feet away from a wall on a level driveway with two pieces of tape placed on the wall 36” above the ground. Then I aimed the lights so the top of the light beam was at 36”.

Thanks very much to Jeepster2k3 for this posting. I recently purchased a preowned 2014 Unlimited Rubicon X and found 4 out of 6 jaw areas on the 2 headlight mounting rings were busted out. In addition to the adjustment posts which I fixed exactly as described above, I also had to repair two of the non-adjustable posts on one side.

I used a variation of the same procedure. I first picked up a 2 ½ inch long #10-24 ?Hanger Bolt? which is a bolt with threads on each in: machine threads on one end, and course ?wood? threads on the other end. The wood threads were different than on the metric OEM posts, but they are the same diameter so had no problem screwing into the plastic base. Additionally, I used a #10-24 cap nut to create a temporary hex head so that I could screw the hanger bolts into the plastic base using a ⅜ inch socket wrench.

I used JB Kwik Weld which sets up in 6 minutes and withstands 230 degree F to glue 3/16 inch x 1 inch diameter washers on the back of the broken plastic headlight mounting ring. And again, I used #10-24 Nylon Lock Nuts on front and back to hold everything in place. I also used two washers in front #10 washer and a slightly larger ¼ inch washer.

My Jeep has a 3 inch lift and I?m running 35? Toyo MTs with 28 psi so that the distance from the ground to the top of the light beam near the headlights was at 44 inches. To set the proper angle, I parked 25 feet away from a wall on a level driveway with two pieces of tape placed on the wall 36? above the ground. Then I aimed the lights so the top of the light beam was at 36?.

Sorry again to revive this post, but I just came across it and wow what a lifesaver… thank you! I already bought some expensive LED lights and didn’t want to have to buy the entire assembly with bulb. Not to mention the reviews on those things are garbage.

My bolts that went through were all bent up from where the plastic support was busted and someone kept torquing them down. I ended up buying some allen head bolts to replace them at Ace, put a washer on either side of the ears of the basket, and a spring behind each bolt. The springs put tension behind the basket to hold it steady. I saw some fractures in the plastic cage and filled up all the support holes with epoxy. It really makes you wonder why some reputable company doesn’t sell an upgraded basket!

If anyone comes across this thread, stay away from these: https://www.amazon.com/gp/product/B01N9YLIFY — they look really well built, but don’t fit inside the headlight opening… even taking it apart and sliding it behind the grille, they sit too far back and just don’t work. Do the mod yourself and save yourself the time and money. It works great!