Tonight while following the headlight removal instructions from Pelican Parts TO A "T", (my first mistake, apparently), I was turning the mechanism the wrong way (though the exact correct way according to pelican parts), and ultimately all the little teeth on the wheel broke themselves off and rendered the release mechanism 100% useless. I kept going because the tutorial said to "not be surprised if it takes considerable force to release", or something to that effect. I took a shot in the dark on the other side and rotated the exact opposite way than the instructions recommended. Naturally, it worked right away. Unfortunately, not before I tried the incorrect/recommended way the first time. I ground enough of the teeth off that when I tried to take it out a second time because I forgot to put the rubber cover back on the high beam bulb, it's as thoroughly broken and useless as the drivers side now.
LONG story short, they're both broken in place.
Does anybody have any bright ideas as to how I can ever get these headlight housings out again?
Thanks,
Jeremy

 

Unfortunately I don't have any suggestions to help you, but was curious what is the correct way to release the headlight. Is it counter clockwise or clockwise?

 

Clockwise for drivers side. Counter clockwise for passengers. A million videos on YouTube. Silly me; I trusted the pelican parts article she didn't bother to research further.

 

You'll need to remove both fender liners and get a long flat screwdriver to push the locking bar flat, or back down... and push-out both clusters. Then, you need to go on eBay and get both slide trays from a boneyard. Buy the trays NOW...

 

thanks! Sounds like you're confident that is a definitive solution
I appreciate your help.
A few online Porsche parts retailers have the trays for 60's each. I'll check eBay first. Thanks again!

 

If you can't get to them via the inside of the fenders - perhaps (not certain, but from memory..) removing the air-filter housings might provide access through the engine compartment. Certainly remove the beauty trim inside the engine compartment and take a look.. that parts easy.

 

Deilenberger is correct - the best access is thru the engine bay, by removing the intake panel.

 

Update: couldn't get any access through the fenders after removing the liners. After researching the air box removal process, I finally decided to try the easiest thing I could think of. Here's my 10 second solution: stopped by my brothers shop and used a Snap On extended pic tool. Probably close to 16". About a 45* angle at the tip. Used a plastic wedge to maintain a little gap between the bumper and the headlight and used a flashlight to see what I was doing. Simply reached straight in (from the front of the bumper, pointing straight back) and used the pic tool to rotate (pop) the bar down, and that's it! Did both sides in under a minute. I have new trays and gaskets in the mail, so I'll use the same method when they get here to swap them in. Simple!

 

I love it when a plan comes together!

 

Me too! Is that DIY Dan?

 

It is! Good work on finding a solution the "do it your damn self" way!

 

thanks! Love your videos. I've always been a DIY guy, and your videos helped make taking on an older cayenne a less daunting prospect!

 

Cool thanks! Glad to hear that my videos are helpful.