changing rear light bulb - HELP!

[dave sutton]

I need to replace a rear light bulb but am foxed as to how to do it. I can't get access from inside the clam as the nuts just spin the thread round so the heads are clearly not captive. Presumably access is from the outside but I am worried that I will break the perspex if I try levering in the wrong place. If it's in the build manual, I can't find it, what's the secret please?

[kenloen]

You need to hold that thread still and get the nut off. 4 nuts and the inner cover panel comes off, the bulb housing then clips in.

[dave sutton]

kenloen said:

You need to hold that thread still and get the nut off. 4 nuts and the inner cover panel comes off, the bulb housing then clips in.

I hear what you're saying and if I have to I'll try that - it's just that doesn't seem right from an engineering point of view. You never turn a nut or head unless you have access to the other end, how else can you tighten it? If the heads are originally captive and age has broken the fix, OK, I will do whatever it takes and sort out a retrofit that will avoid future problems. I still wonder how I would replace the perspex lens part should the occasion arise?

[S26VE P]

the perspex lens is a complete unit (http://www.ebay.co.uk/itm/Ford-Mondeo-mk-1-saloon-drivers-side-rear-light-complete-/300896354471?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item460ed200a7) for example.

[stevegto3]

Ive had issues with the cluster removal for bulb changes, so I can only tell you what my issue was and if that might help. My issue was slightly different in that the nut had rusted to the thread, even with loads of WD40 it wouldn't budge. So when I tried to undo the nut, the tread part turned instead, so in effect the the cluster came off without the tread bolt attached. From what I remember its not a bolt, but just screwed into the plastic mounting in the cluster housing.

Maybe the only option would be to cut off the nut, remove the cluster and then un screw the bolt in the cluster housing and replace with new ones?

[dave sutton]

Oh well, what I'm basically hearing is that I'm up against rubbish design - if I can find an elegant modification I'll post some details.

[AMG Merc]

It might be a plus that they're spinning! If I'm careful I can get the lens off with leaving the bolts in situ. Unscrew the bolt head with spanner/pliers and simulataneosuly try to lever off the lens.

[TuxMan]

Bad news mate , unfortunately looks like you will need a new light as I had this problem and in the end I just ripped it off and chucked it all away as it was all rusty inside !!!!!

Tux

[mgbond]

stevegto3 said:

Ive had issues with the cluster removal for bulb changes, so I can only tell you what my issue was and if that might help. My issue was slightly different in that the nut had rusted to the thread, even with loads of WD40 it wouldn't budge. So when I tried to undo the nut, the tread part turned instead, so in effect the the cluster came off without the tread bolt attached. From what I remember its not a bolt, but just screwed into the plastic mounting in the cluster housing.

Maybe the only option would be to cut off the nut, remove the cluster and then un screw the bolt in the cluster housing and replace with new ones?

Yep, it's a large thread that goes into the plastic part of the light. In order to remove mine I can only remove some nuts the rest to unscrew form the light as the nuts are rusted on.

[dave sutton]

Thanks guys, it wasn't so bad when I realised the nut wasn't spinning uselessly but was unscrewing at the lens end. In the end I found it wasn't the bulb gone, just bad corrosion on the contacts. Having sorted and fettled the nearside, I thought a preventative check on the nearside would be wise, only to find someone else had had a struggle and not been so patient. The upshot is that I need at least three of the fixings for the light fitting. Like these:



What do I call them to order some more?

[jdearden]

I may actually have some of these in my tool box from my old broken lights. I'm not at home till Sunday but will look.
If not I do have some fully tinted lenses in the shed complete will all fittings etc.

[dave sutton]

jdearden said:

I may actually have some of these in my tool box from my old broken lights. I'm not at home till Sunday but will look.
If not I do have some fully tinted lenses in the shed complete will all fittings etc.

Thanks, its only the fasteners I need, everything else is fully serviceable.

[TuxMan]

I bought 2 barns new lights for £20 off eBay :-))

[dave sutton]

Sorted! M5 x 40mm Wood to Metal Dowel Screws have done the job nicely with the aid of some Loctite, new locking nuts and plenty of Waxoyl to protect them from road sludge. I have a few left over if anyone else has need of them.

Edited by dave sutton on Thursday 23 May 15:30

[mgbond]

dave sutton said:

Sorted! M5 x 40mm Wood to Metal Dowel Screws have done the job nicely with the aid of some Loctite, new locking nuts and plenty of Waxoyl to protect them from road sludge. I have a few left over if anyone else has need of them.

Edited by dave sutton on Thursday 23 May 15:30

Got a link to where you got them as I would like to sort mine at some point.

Cheers

[dave sutton]

mgbond said:

Got a link to where you got them as I would like to sort mine at some point.

Go to: "http://www.theinsertcompany.com/wood_to_metal_dowels.shtml", click on 'buy online' and scroll down to Hanger Bolts.

I chose M5 x 40mm and it worked out well. The woodscrew end is smaller than the thread in situ but they are long enough to drill a small pilot at the bottom of the blind hole in the light fitting and wind it down to leave the right length of the M5 end sticking up. I filled the gap with Loctite and left it for a day to set. I daresay next time they might unscrew from the wrong end but either way we'll gain access and it will be refixable.

[Metalman]

My advise would be to use plenty of copper slip on the thread and stainless nuts, hopefully you won't have the rusting problem again.

[AMG Merc]

Has anyone fitted replacement led bulbs to their rear lights?

[mgbond]

AMG Merc said:

Has anyone fitted replacement led bulbs to their rear lights?

I tried straight replacements but they didn't work. It needs extra bits to work. But I couldn't be bothered

[Zoobeef]

I fitted led brake light bulbs as one kept blowing.
Straight swap although the pos and neg need to be the correct way round to work, which confused me for a few minutes. Thought I'd bought a dud