DIY: B6 A4 - O-Ring Fix for S4 and E-Code Bi-Xenons

[JJPA4SE]

Seems like there are random bits of info everywhere but not a complete how to...

Total Time:
5-15 Min.

Tools Needed:
T30 Torx to remove Headlight
T20 Torx to remove Top Gear Assembly
Phillips or 6mm Allen Key to turn adjustment screw
Blue Painters Tape (If you want..)

1. Remove Light from car. I put blue painters tape on the bumper under the light so the bumper doesn't get scratched.

2. Identify Location


3. Unscrew (T20 Torx) screw & Remove Top Gear Assembly


4. Turn Light Upside Down and pull out Gear Shaft (So dirt does not go into the housing). Wipe dirt from around opening while upside down...


5. Remove Old O-Ring and Install New O-Ring on Gear Shaft...


6. Reinstall Gear Shaft with New O-Ring... Some other post's recommend putting Graphite Lube on O-Ring at this time. I have not done this and they seem to be working OK.


7. Reinstall Top Gear Assembly (T20 Torx)... same as Step 3

8. **Optional** Carefully Turn Adjustment Screw both Left and Right to make sure it's in good. Make sure to leave adjustment screw in same place as before so height of light is not changed. Final tweaks may be needed anyways once lights are reinstalled anyways.

9. Cleanup and reinstall Headlights!!


Good Luck and preform fix at your own risk. Be careful not to break anything, it wont be my fault...

[grifter]

Does the light simply pull-out? Sorry, newbie and long time lurker asking silly questions.

[QuattroRocket]

The light is removed with 4 torx screws, 2 on top front and 2 on the back of the housing.

So my question is where do you get the o-rings ? Is there a part number or size that I can use to go find em somewhere ?

[nananana4k]

you can get the orings at home depot, i think in the plumbing section. Theres even a pack that has different sizes.

[dparm]

Resurrecting this...what is the point of this DIY?

[lfloodt]

the point is that the original O-rings are too small, allowing moisture in and leading to condensation in your headlights all the time. I had the problem, did the fix(did only take like 10 minutes) and now I'm condensation free! note- the turn the headlight upside down part is good advice, the gear assemblies get really dirty, and you don't want that going into the headlights.

[dparm]

Gotcha. Where do you get the new O-rings? Part number?

[lfloodt]

I got them at home depot, in the plumbing section. the brand is Danco, #6 O-ring, 7/16" O.D. x 5/16" I.D. part #96723. they come in a 10 pack for like $2.