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Thread: Need a clip to fix your headlight self levelling system ?

  1. #161
    <tuffty/>'s Avatar
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    Quote Originally Posted by BuuBBa View Post
    Could someone please explaine where this clip is located? Or picture would be easiest way to see..
    Page 3 post #145

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  3. #162
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    Quote Originally Posted by <tuffty/> View Post
    Page 3 post #145

    <tuffty/>
    Thanks!

    Last time I checked the whole topic (with my mobile phone) but I didnt notice that..


    Unfortunatelly that wont help me, cause my headlights has broken plastic white nut(?) which is straight behind the housing. It has some threaded rod inside of it and if You touch the rod the whole inner section will move.. Hard to explain so I'll try to get some pics..

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    Quote Originally Posted by BuuBBa View Post
    Unfortunatelly that wont help me, cause my headlights has broken plastic white nut(?) which is straight behind the housing. It has some threaded rod inside of it and if You touch the rod the whole inner section will move.. Hard to explain so I'll try to get some pics..
    You mean like this

    It's the beam adjuster ... it looks like, at some point in my car's history, something has got on the plastic which has eaten away at the plastic cogs.






    This is from and old Xenon unit off my car, I've dismantled it. I'm thinking, because I still have the adjuster I can epoxy it back on. I have been looking for a supplier of new bevelled cogs, with the same tooth pitch etc.

    Then all you need is to drill the hole out to fit and epoxy it on. et voila don't have to spend £600 at Audi for a new headlamp.

    Found another photo of the dreaded clip in situ ...


    Hope this helps.

    Liam

    S3 AMK 2002. Only 203 BHP left in my poor little engine, currently searching for the 7 missing horses.
    Mods: Powerflex bushes at the front and rear, 710P DV, ambient light module, Badger5 V3 TIP, S2000 Filter.

  5. #164
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    vfr800, thats excactly what I have now..
    My self leveling sensor arm is unpluged (by the last owner) and I guess that the height cant be adjusted if that part is broken. Or am I wrong?

  6. #165
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    Quote Originally Posted by BuuBBa View Post
    vfr800, thats excactly what I have now..
    My self leveling sensor arm is unpluged (by the last owner) and I guess that the height cant be adjusted if that part is broken. Or am I wrong?
    There are two parts.

    1) Automatic level adjustment.
    The sensors on the front/rear allow the car to determine the suspension level, for example if you have put a couple of dead bodies in the boot, the rear will be lower than the front, the sensors tell the 'level adjustment controller' these values and the controller adjusts the headlight beam, using the motors, on the headlamps accordingly.

    2) Manual adjustment on the headlamp.
    The manual adjusters are there to point the headlamps in the right direction in the first place. There's a procedure, with the car level i.e. nominally loaded with 3/4 tank of petrol, nothing in the boot and someone in the driver seat (or something like that). to tell the motors to position at their default 'home' position.

    You can then, with the proper equipment or or bodge against a garage door, align the headlights to point in the correct direction when the car is 'level'.

    If the sensors aren't sensing then the automatic adjustment isn't going to work.

    If the adjuster nuts are fubar like my pics above then the headlights are going to flap around like a very flappy thing doing something flappy in a flappy place at a flappy time.

    Probably an MOT fail on both counts!?

    Liam

    S3 AMK 2002. Only 203 BHP left in my poor little engine, currently searching for the 7 missing horses.
    Mods: Powerflex bushes at the front and rear, 710P DV, ambient light module, Badger5 V3 TIP, S2000 Filter.

  7. #166
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    Quote Originally Posted by vfr800 View Post
    I have been looking for a supplier of new bevelled cogs, with the same tooth pitch etc.
    try www.hpcgears.com and email them with full details of the gear you require, if they do not have an off the shelf solution they will have them made up for you.

    I would imagine however these gears will be of standard dimensions and therefore you will get a new one easily. They simply press fit onto the knurled shaft and do not require any glue to secure them.

    here is the form you need:

    http://hpcgears.com/newpdf/bevel_technical_request.pdf

  8. #167
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    Quote Originally Posted by sideways steve View Post
    try www.hpcgears.com and email them with full details of the gear you require, if they do not have an off the shelf solution they will have them made up for you.

    I would imagine however these gears will be of standard dimensions and therefore you will get a new one easily. They simply press fit onto the knurled shaft and do not require any glue to secure them.

    here is the form you need:

    http://hpcgears.com/newpdf/bevel_technical_request.pdf
    Thanks that's proper useful

    Could save people hundreds of pounds if they can fix them that easily.

    EDIT: Weird I didn't see the form/PDF on the original post ... only when I replied.

    Liam

    S3 AMK 2002. Only 203 BHP left in my poor little engine, currently searching for the 7 missing horses.
    Mods: Powerflex bushes at the front and rear, 710P DV, ambient light module, Badger5 V3 TIP, S2000 Filter.

  9. #168
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    Hi Ya Guy's my headlights have seen better days , when i changed the left bulb the projector lens was moving and when i got to the right i was a bit heavy handed and something snapped inside the headlight . i think my manual adjusters are ok, would my lens flap up and down if it was the clip thats on topic. i will have a proper look over the weekend. can i replace without taking the unit apart or would they need stripping to get this new clip in when available ? if it needs stripping would a magnetic screw driver manage the job to save stripping them down.

    Cheers


    EDIT: Right ive been out and had a quick play and asked my own question really, bit of a dumb question for me to ask ^^^^^^ . both gears on the manual adjusters on both sides are good Pheeew but both clips are dead ! Looks like both units will need to come out to be fixed i think i will wait for the new part being desgined dont really fancy doing it twice. M.O.T is due in august so hopefully the clip steve is working on will be available by then.
    Last edited by Nick090884; 16th June 2012 at 17:26.

  10. #169
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    No further update yet, just waiting on the prototypes being made. I am not however willing to push it as there being done for free as a favour so we just need to be patient for now. Hopefully though we wont be waiting too much longer

  11. #170
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    I'm in to for them!

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  12. #171
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    Well chaps..... the prototypes are now complete, I had an email today advising they will be sent out to me so once they come I will get them fitted and get some photos then report back with the results !

    Thanks for your patience !

  13. #172
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    sounds good! cant wait for the results.
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    pm me for more info..

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  14. #173
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    I'd defo be interested, mines held on with cable ties! S3 addict
    Audi S3 210bhp (Remapped to 260+), Black, Forge DV, Forge Boost hoses, Forge PCV hoses, K+N Induction Kit with Stainless Steel Heat shield, Powerflex front wishbone and anti-roll bar bushes, EBC grooved front and rear discs and Red stuff Pads, N249 Deleted
    ))))))))))))((((((((((((

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  16. #175
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    I changed my xenon bulbs today and one of the projectors is flapping about inside the housing so i guess i'm in..

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  17. #176
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    Hi all I think mine are f****d as the chrome inside the headlight has come away from the plastic mould and not sure if this is the cause but I'm in for a few anyway. I'll get a few pics so you can see what I mean.

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  18. #177
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    Guys, I took the plunge and went for a repair on my headlights at the weekend, aiming to replace both the broken auto levelling clips with the Renault ones that SuperKarl recommended, and all went very well! The Renault clips set me back by a grand total of £1.20 inc. VAT, and quite literally fit like a glove. I took some pictures of the process, and will aim to get these up this evening!

    Only problem now is, I'm having alignment/levelling issues. Despite all the motors being connected correcly, and all the sensors being hooked up, the levelling motors whir when the lights are powered on, but barely any movement occurs. The lights need re-aligning for sure after all the work I've done, and this is what I understand of the process to do this:
    - car needs to be hooked up to VCDS and put into 'Learn Mode'
    - headlights need to be manually adjusted to a level, and then the Motors will 'Learn' this level
    - once this is complete, auto levelling should work correctly

    Now I know the above is dependent on the sensors working correctly, and these are intact and not damaged, however, my car is lowered, quite a lot... Some of you may have seen and will vouch for this...! Could this put the sensors out of range, affecting the auto levelling? I don't want to end up taking the car in for headlight alignment and then be told it can't be done...

  19. #178
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    Any update on the prototypes?

  20. #179
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    Quote Originally Posted by AJD S3 View Post
    Guys, I took the plunge and went for a repair on my headlights at the weekend, aiming to replace both the broken auto levelling clips with the Renault ones that SuperKarl recommended, and all went very well! The Renault clips set me back by a grand total of £1.20 inc. VAT, and quite literally fit like a glove. I took some pictures of the process, and will aim to get these up this evening!

    Only problem now is, I'm having alignment/levelling issues. Despite all the motors being connected correcly, and all the sensors being hooked up, the levelling motors whir when the lights are powered on, but barely any movement occurs. The lights need re-aligning for sure after all the work I've done, and this is what I understand of the process to do this:
    - car needs to be hooked up to VCDS and put into 'Learn Mode'
    - headlights need to be manually adjusted to a level, and then the Motors will 'Learn' this level
    - once this is complete, auto levelling should work correctly

    Now I know the above is dependent on the sensors working correctly, and these are intact and not damaged, however, my car is lowered, quite a lot... Some of you may have seen and will vouch for this...! Could this put the sensors out of range, affecting the auto levelling? I don't want to end up taking the car in for headlight alignment and then be told it can't be done...
    Same both here,i went ahead and ordered 2 clips from Renault but the ones i got look nothing like the ones Karl pictured.

  21. #180
    got an S3 8L: living the dream

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    Quote Originally Posted by Ads_AudiA3 View Post
    Any update on the prototypes?
    Sent Steve the prototypes about 4 weeks ago. Think he is just very busy.

    Hopefully Steve won't mind me doing this, but here are some pics of the prototypes to keep peoples appetite until Steve can give an update. I don't know much about how they work or are fitted (you need Steve for that if you don't already know), but I cannot see these things breaking in a million lifetimes. They really are rock solid:






    2002 S3 8L AMK

  22. #181
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    Do want! Looks like i'm going to have to take headlights out to the renault clips anyway,so do i wait a bit for these to be ready .....

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    Shane, I did the same, ordered some clips from renault and they don't look right at all. Firstly the ones I have are white secondly the ball joint for the motor fits very poorly, and lastly, when it is installed inside the headlight the ball end of the motor doesn't even fit in the renault clips. I didn't bother to do the other side, just left it as it is and will wait for the clips Steve has been working on.

  24. #183
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    Quote Originally Posted by chazza55 View Post
    Sent Steve the prototypes about 4 weeks ago. Think he is just very busy.

    Hopefully Steve won't mind me doing this, but here are some pics of the prototypes to keep peoples appetite until Steve can give an update. I don't know much about how they work or are fitted (you need Steve for that if you don't already know), but I cannot see these things breaking in a million lifetimes. They really are rock solid:
    They're looking awesome, lets hope that they have been tried and tested and have the thumbs up! MOT due in August and could do with the lights working properly!

  25. #184
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    Quote Originally Posted by Ads_AudiA3 View Post
    Shane, I did the same, ordered some clips from renault and they don't look right at all. Firstly the ones I have are white secondly the ball joint for the motor fits very poorly, and lastly, when it is installed inside the headlight the ball end of the motor doesn't even fit in the renault clips. I didn't bother to do the other side, just left it as it is and will wait for the clips Steve has been working on.
    Very same as me Ads,wrong clips,bad fit and scrapped knuckles trying to fit - i gave up with lots of Grrrrr-ing!!

  26. #185
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    Quote Originally Posted by Shane-Ireland View Post
    Very same as me Ads,wrong clips,bad fit and scrapped knuckles trying to fit - i gave up with lots of Grrrrr-ing!!
    I had the same lads , i got a white clip that had a pin like centre. had to cut em drill em and countersink the screwhole got them on and working but not happy about them. think the left has come lose already, cant wait for the clips cant see them being made and sent out before august which is a bummer because ive a mot to due then. worth waiting for if i can scrape by my mot with these clip in.

  27. #186
    got an S3 8L: living the dream

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    a friendly request for patience from our friend Steve:

    "sorry I have not done anything yet, we have had a major job go tits up at work and I am working all teh hours under the sun to try and get it sorted out

    Hopefully I should be able to do something with it in a couple of weeks time once I have cleared my feet again.

    I have not even had time to get on the forum recently so if you wouldnt mind updating people on the post for me I would appreciate it !

    Cheers
    Steve"
    Last edited by chazza55; 24th July 2012 at 14:51.
    2002 S3 8L AMK

  28. #187
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    Hoping that these are still being produced as my nearside is broken.

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    Can anyone tell me if there are still any left from the original batch made?

  29. #188
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    Count me in too! Also any joy with the little gear wheel ones towards the top of the headlight cos one of mine is fooked!!


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  30. #189
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    Also anyone got a how too for removing the headlight units? Thanks guys

  31. #190
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    Quote Originally Posted by jimbob442 View Post
    Also anyone got a how too for removing the headlight units? Thanks guys
    Remove front bumper ( 2 screws under Neath, screws in wheel arches and then remove the 4 retaining plugs on top by pushing the pin through)

    Then just unbolt and unplug headlight. Takes 20 minutes

  32. #191
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    Any news on these yet??

  33. #192
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    Good news, got through the MOT without the need for clips!! still want some though so I can fix my headlights!

  34. #193
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    Yes Please! Just what I need, mine has cable ties holding it together!!

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    Audi S3 210bhp (Remapped to 260+), Black, Forge DV, Forge Boost hoses, Forge PCV hoses, K+N Induction Kit with Stainless Steel Heat shield, Powerflex front wishbone and anti-roll bar bushes, EBC grooved front and rear discs and Red stuff Pads, N249 Deleted
    ))))))))))))((((((((((((

  35. #194
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    ETA.
    very interested in these, headlights are in bits on kitchen table not in car as they should be!!
    cheers matt

  36. #195
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    IF you do not mind sending to OZ please add me to the list

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  37. #196
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    Not sure if this will be of value to many of you, but I managed to fix my headlight levelling fully, once and for all over the long weekend!

    Weirdly enough, I actually modified some headlight adjuster clips from an A3 8L that I grabbed from the local scrap yard. It took me a good 2 hours to modify each clip carefully, but they work like an absolute charm. The design of the A3 clips is fairly similar - the only real change you need to make is add some more plastic, or use a washer or something, to the back of them to match the depth of the originals (unfortunately I didn't get any pictures, was rushing just to get the job finished as it was). The end result is working adjusters!

    This was my third attempt at fixing my headlight adjuster issue:
    1. The first time I tried to repair the old clips - snapped again immediately upon rebuilding the lights
    2. The second time I replaced the originals with SuperKarl's suggested ones from Renault - despite promising results at first, unfortunately these just didn't work at all for me in the end. The motors would continuously pop out from the clips as soon as any adjustment started.
    3. Modified some A3 clips - success!

    As I'm sure you can tell from the above, I completely understand how annoying this issue is! I don't know how far along Steve is with fabricating custom clips, they really do look great so I hope they'll be along soon, but if anyone can't wait for these, I'm more than happy to modify some more A3 clips for anyone who'd like some? Simply PM me i anyone is interested. I very much doubt I'll be able to make that many of these though, as the A3 clips aren't amazingly easy to get hold of, so if you are interested let me know ASAP!

  38. #197
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    ~Did you remove the headlights and take them apart to work on the clip AJD?

  39. #198
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    Quote Originally Posted by AJD S3 View Post
    1. The first time I tried to repair the old clips - snapped again immediately upon rebuilding the lights
    Can I ask a question? How were you putting the adjuster back in?

    I know the clips will snap eventually anyway but I think a lot of them break when people are putting the electric-adjuster back in by trying to push the ball on the adjuster straight into the groove on the clip - forcing the two sides apart ... thus it snaps.

    To put the adjuster back in I found you have to insert the adjuster at a funny angle so the ball slides in from one end of the clip. Then you can rotate and lock the adjuster.

    Just wondering ...

    Liam

    S3 AMK 2002. Only 203 BHP left in my poor little engine, currently searching for the 7 missing horses.
    Mods: Powerflex bushes at the front and rear, 710P DV, ambient light module, Badger5 V3 TIP, S2000 Filter.

  40. #199
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    Hi are these finished yet as we haven't heard anything for a while.

    Cheers

  41. #200
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    Hi, I am quite desperate for these now and there hasn't been any more info whether they are ready or not, does anybody else know of any other options availiable to me.

    Cheers

 

 
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