Replacing headlamp adjusters

[marcus]

I know this has been the subject of a number of previous posts, but I think it would be useful to get some clarity on it, and add it to the FAQ.

Most of the headlamp securing fixings on my 1985 GTL (dual headlamp setup) are cracked or broken. Miraculously, this doesn't seem to affect their aim too much but I'd like to sort it out.

Typical dual headlamp setup is main- and dipped-beam outers, smaller main-beam inners. Outers use H4 (dual-filament) bulbs, inners use H3 (single filament) bulbs, same as the foglights, which is a bit of a pain seeing as H3 fitment doesn't seem to be available in the high-perfomance sector eg Night Breaker etc.

A big problem is availability of parts. Some are purportedly available on eBay from one seller in Greece claiming to sell the genuine article; one of them is available from VW Heritage; two are available from VW Classic Parts in Germany. Anecdotal evidence on various VW forums suggests that some of these 'new old stock' genuine parts have aged to the extent they crack when fitted.

There has been talk about parts from some models of BMW being interchangeable, someone on this forum made mention of buying some from GSF.

What I'd like to do is establish what parts are suitable and available, with part numbers and suppliers, whether VW or BMW or whatever, and create a list of them to put on the website for future reference.

So, any input from anyone who's changed theirs would be much appreciated, can anyone help?

Below are the specific part numbers, quantities and fitting positions for the typical dual headlamp setup.

According to ETKA, page 216-00, my car needs all these parts (diagram part labels in brackets):

533 941 133 (item 7, outers) x 2
533 941 141 (item 8, outers) x 4
534 941 133 A (item 7A, inners) x 2
533 941 141 A (item 8A, inners) x 4

Making for a total of 12 parts.

Looking at the car, there are 8 fixings at the top, two per lamp, and 4 at the bottom, one per lamp.

Looking at the ETKA diagram, per outer lamp, there are two of number 8, top outer side and bottom inner side; and one number 7, top inner side.

Looking at both the car and the diagram, per inner lamp, there are two of 8A, both on the top; and one of 7A at the bottom inner side.

[essextom]

I got a set of mk2 golf/ t2 adjusters from eBay. They are exactly the same as Rocco ones apart from the plastic bit at the frame end which I just swapped over and used my originals. The non adjustable (without thread) item can't be used because u can't swap over the frame end, I did swap over and use the new light end. I can post some close up pics of it in morning if that will help anyone?

[essextom]

These are my Frankenstein adjusters.

[marcus]

Interesting, these are the parts listed for Golf Mk2, two of the part numbers are the same as the 'rocco (barring the leading three digits which identify the model), seems to intimate they're all interchangeable.

adjuster.jpg

[GTXTRA]

All useful stuff.

For what it's worth I've happily dealt with the ebay seller nkautomotive in Greece - never had a problem and infact boosted my stock of adjusters via them a few months ago, all the bits look as new and in completely servicable condition.

I tend to buy a few different items from them at the same to time to keep the postage down and the stuff turns up pretty quickly and always securely. Much more convenient for me than driving to dealers who can't be arsed with the older cars or the gsf/eurocarparts shops with zero parking/inconveniently located.

[ThomasD]

I've also bought parts from Nick in Greece and have never had any problems.

If you buy NOS adjusters, it's not that the plastic is old, but rather that it's plastic to begin with. It's not a great design. You need to rotate the adjuster to install it in the headlight frame, and that is where it's very easy to break the new adjuster, especially if you try to do this with a wrench or pliers. I found the fit of the new adjuster just a bit too tight, and that by sanding or filing the adjuster slightly to open up the gap between the circular disc and the plastic arm on the adjuster, you don't have to apply quite as much force to lock it into place in the headlight frame. Also, use a little bit of grease as well. By doing so, you will be less likely to break the new adjuster when you install it.

The alternative is to make you own adjusters using a stud along with some nuts and washers.

Regards,
Tom

[The Milkman]

Just in case this helps anybody else out.

I needed to replace the joints/adjusters on my headlights and find new ones to fit new inner lights to my rocco (it's single headlight at the minute). The ones for the main headlights (533941133 and 533941141) I got from VW Heritage , not cheap but at least they were available.

I couldn't find any for the small headlight units (533941133A and 533941141A) but I think I've found something pretty close, Mk2 Golf ones. The first set I found were £17 for three, managed to find them for £6 a set of three on eBay.

I haven't tried them yet as my car is still being welded but they look very close, right lengths, the plastic bucket on one style is slightly longer but it shouldn't make any difference to them fitting and working.

[The Milkman]

I forgot the link

http://www.ebay.co.uk/itm/Headlight-adj ... OC:GB:3160

[marcus]

Thanks for that, will take a look.