Replacing fog light lens on 1990 80Q (and similar - Hella H3 type)

[jensen@maxwell.mml.mmc.com (Jim Jensen)]

For the general edification of the net....

I just replaced the lens on the left foglight with a new one from
Linda @ Carlsen, here is an overview in hopes of making it easier for
the next person that needs to do it.  (the lens had a rock chip -->
pinhole through the front of the lens)

Buy a new lens from Linda @ Carlsen for ~$52.00 + 3.00 shipping.
  (whole new lenses were quoted at between $70 and $120 from various
   other sources... don't remember who said what.)

take old lens out of car and seperate front from back w/ two screws on
side.

remove bulb (w/o touching lens if the bulb is not burnt out)

completely unscrew the adjustment screw from the adjustment holder

There are two black rubber "things" that hold the bulb holder/interior
lens to the outer lens/cover (plastic).  You can either:
	-demolish the plastic enough to get the interior piece out
	-use a standard screwdriver to wedge between the plastic outer
	 holder and the "thing".  Then force the "thing" in (only need
	 to go about 1/8 inch).  Then the interior piece will slide
	 right out - it is very clever the  way they build these.

Now for the hardest part - If I had know better I would have just
ordered another one from Linda....  The adjustment screw (controls the
height of the beam) is somehow permanently attached to the plastic
outer lens/cover.  This is to water proof the hole that the adjustment
screw goes through.  I basically removed the case by brute force (ie:
vice grips and big pliers - no match for brittle plastic).  It turns
out that the screw looks like this:

	      ~~~|
	######===|///////////////
	      ~~~|

Where:
	#### is a knurled section of the screw,
	==== is a smooth section, covered by:
	~~~~ a rubber grommet and plastic washer
	  |  a piece of the screw, which holds the rubber grommet and
		washer in place
	//// ascii rendition of the threads.

A white plastic piece is friction fit over the ####.  I removed it by
putting two nuts onto the end of the screw, tightening them together,
and using one pair of pliers on that, and the other on the white
piece, and twisted until it came off.  Then insert into the new case
via friction fit.  As I said before, given this knowledge, I would
have just bought a new screw - how much could it cost? (don't answer
that - it was rhetorical)


After that, it just snaps together in the logical inverse of the above
described procedure... (really).

If need to do this, and have any questions, feel free to email.  It is
really pretty easy to do, and you will understand the above better
after looking at the pieces.  But the hints given will make it fast
then next time.  Now if I could just find a way to change the air
filter that was as easy....... 

	Jim Jensen	jensen@mml.mmc.com