Headlight ballast R&R?
Headlight ballast R&R?
Looking for tips on changing a headlight ballast on a '08GT: I have the headlight housing on my bench, with the ballast cover removed, and the bulb wire disconnected, and the yellow 12V feed plug to the ballast unplugged, and the ballast mounting screws out, so the ballast is loose/ready for removal... but dang if I can figure out how to fish the bulb wire out and the new ballast's bulb wire back in... there's seemingly no room inside the housing to do so due to the bulb reflector and such. Anyone here figured out the trick to it? I pulled the cover off the ballast to see if the bulb wire could be disconnected there, but that doesn't look advisable.
After some more (much more) examination of the patient, all I can figure is Bentley loads the ballast in before installing the inside lighting fixtures... and once all the guts are installed in the housing, then affixes (glues?) the lens to the housing. So short of somehow removing the lens and removing the fixture guts out through the lens holes to then change the ballast, it looks like there may be a work-around solution by drilling a couple of access holes in the housing plastic under the ballast mount to gain access to remove the two mounting screws for the "dip solenoid"... and once that solenoid is loose to allow it to be moved out of the way inside the housing, that may allow enough room to fish the bulb wire out... eh?
Update: I successfully removed the old ballast and have the new ballast installed. Right or wrong, here's what I did additionally:
1) Removed the two phillips head screws securing the bulb reflector. This allowed the bulb reflector to be loose in the housing which allowed enough room to remove the solenoid out the back of the headlight housing. The two reflector mounting screws loosen hard... I drilled a 1/4" hole in the housing to get a straight shot at the "upper screw" to put enough power to it to crack it loose.
2) Removed the solenoid. This wasn't pretty: I trimmed away about a 1" square in the housing plastic under the ballast mount / above the solenoid to gain access to the solenoid mount screws and allow enough room to wiggle the solenoid out the back of the housing.
3) Removed the metal hoods on the ballast bulb connections. This allowed just enough room to fish the ballast's bulb connector though the solenoid mount location.
So at this point, it's finish assembling and see if it works.
1) Removed the two phillips head screws securing the bulb reflector. This allowed the bulb reflector to be loose in the housing which allowed enough room to remove the solenoid out the back of the headlight housing. The two reflector mounting screws loosen hard... I drilled a 1/4" hole in the housing to get a straight shot at the "upper screw" to put enough power to it to crack it loose.
2) Removed the solenoid. This wasn't pretty: I trimmed away about a 1" square in the housing plastic under the ballast mount / above the solenoid to gain access to the solenoid mount screws and allow enough room to wiggle the solenoid out the back of the housing.
3) Removed the metal hoods on the ballast bulb connections. This allowed just enough room to fish the ballast's bulb connector though the solenoid mount location.
So at this point, it's finish assembling and see if it works.
Last edited by W. M. Hellinger; Mar 4, 2020 at 03:21 PM.
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Hedonistic
996 Turbo / GT2
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Aug 6, 2010 11:05 PM




