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      10-03-2018, 12:37 PM   #1
Alexxv
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DIY - Broken headlight tabs repair (OEM Kit)

I bought the kit and couldn't find a DIY So I made one


This is a fairly common problem since BMW designed these tabs to actually break during an impact due to pedestrian protection laws.

Having stiff suspension and less than perfect roads could cause these tabs to break.

Fortunately, BMW sells a kit to repair them PN 63116924482 (less than $30) and there is provisions for these new tabs to be screwed into without damaging the headlight so no need to replace the entire headlight (see kit)







In order to make the kit work, you have to clean the broken tabs to make room for the new ones, I did it with a Dremel and it made the job a lot easier/quicker.

Once your headlights are removed, locate the broken tab and clean out the area to ensure proper fitment of the new tab. You need to be patient and test fit new tab as you shave plastic to ensure you are not damaging the new mounting location or the headlight itself.




This first tab for the self-adjusting headlights slides into the existing slot on headlight and uses 2 screws (T20 torx). Once the tab sits properly, hand start the two T-20 torx screws to confirm fitment then run them in. I used a drill on lowest torque setting and it work just fine, be sure to no not over torque these screws are they are self-tappers and they can damage the headlight and the repair.



See pictures (1-3)





This second tab is for the top main mounting of the headlight (uses four T-20 torx screws)

I placed the tab next to it to see how it would fit and how much of the plastic I had to cut/clean. You can also see that the new tab has some grooves to guide fitment.



See pictures (4-5)





Repeat steps above, clean area, test fit and run T-20 screws. (see picture 6)



Once the base tab is mounted, the mounting tab needs to be "loose installed"

First, insert the metal j-nut as shown on picture below and then run the T27 Torx screw but not all the way. This will allow the top tab to move and you will give final torque once installed on vehicle.

(See picture 7)



The third tab is located at the bottom of the headlight.

Locate tab, clean, test fit, and installed the two T-20 torx screws as shown

(See picture 8)



Then insert the metal "L" bracket and run the 10mm screw

(See picture 9)


The fourth tab is located below the blinker bulb on the back of the headlight

Locate tab, clean, test fit, and installed the two T-20 torx screws as shown

This tab has three slots that will clip in to the existing tab so be sure not to cut those.

(See picture 10)


Insert tab and run the two T-20 torx screws as shown then push the metal support insert into plastic tab.

(See picture 11)


That is it, you know have headlights ready to be installed back in the vehicle.

NOTE: Some of the tabs can go on either side headlight, if they specific for the R or L they will have it clearly marked. (See picture 12)
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Last edited by Alexxv; 10-03-2018 at 12:46 PM..
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      01-11-2020, 04:47 PM   #2
TridenTBoy
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Very useful. Used it today.
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      01-23-2020, 12:00 PM   #3
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Quote:
Originally Posted by TridenTBoy View Post
Very useful. Used it today.
Glad I was able to help
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      01-23-2020, 05:06 PM   #4
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Honestly, It's awesome they had the foresight to design provisions in for repairs. I'm assuming they didn't originally mount them with these brackets installed with screws because it would cost them more than molding them right into the housing, like they did.

Great Design BMW(? not sure who actually makes the headlights/was responsible, but either way)
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      01-24-2020, 02:01 PM   #5
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Thanks for posting this! I finally repaired the tabs on my driver side headlight.
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      01-26-2020, 07:33 AM   #6
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Quality diy. Thanks!
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      08-04-2020, 09:10 PM   #7
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Fixed my tabs today. Awesome DIY, much appreciated!
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      08-24-2020, 10:47 AM   #8
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Glad I was able to help some of you...
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      03-08-2022, 08:05 PM   #9
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Brilliant, thanks for posting the pics.
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