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any tips on spinning nut/bolt removal on 240 headlight??? 200 1986

BTDT. More of being pissed off than a monster problem. Grip the nut with something, wrench or ViseGrip, to hold the bolt from spinning. Disconnect all the adjuster things and the wire and you can, IIRC, get the lamp bucket off and out of the way. Then start drilling on the bolt head. I used a small one first, like 3/32 inch, to get a well-centered hole. Follow with a 1/4 or 5/16 inch, whichever is just larger that the bolt thread diameter.

Drill the hole straight into the bolt head, and it will come off entirely.

Next, get a new bolt, about 1/2 inch longer than the old one. Get something that will sleeve the bolt, just long enough to hold the bolt head from sinking in to that now-rounded hold in the mounting plate. I used a piece of vacuum tubing cut a little too long. When you tighten down that bolt, the sleeve allows you to get a wrench on the bolt head; the in-car part looks and works just the same.

Advantage: For me: the repair could be done RAT NOW!, no waiting for epoxy to dry, or running replacement parts. Disadvantage: You gotta have all that stuff to do it, it takes about an hour, and it may or may not work on the other bolts, mine was the upper-inner.

Good Luck,

Bob

:>)






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