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04 2.8 4motion wagon
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Discussion Starter #1
I have looked at several threads on this subject but many links don’t work because they are old. When I was changing bulb on passenger side I noticed that the assembly (reflector) just free floating, and missing covers that previous owner probably broke or discarded. He probably adjusted headlight with a hammer. Anyway, does anyone have a link to video showing this procedure. Would like to see it before I start ripping bumper off, I haven’t been having good luck with plastic pieces on this thing. Thank you.
 

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04 2.8 4motion wagon
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Discussion Starter #2
Did find a pretty good video, all set.
 

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I'm wondering if you can take out the headlight assembly without removing the entire front nose of the car. I know it'd be tight squeeze especially on the b5.5 versions but I'm guessing it could be done. With a bit of patience and crafty maneuvering.
 

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Discussion Starter #4
Was looking at it, would be really tight squeeze. I checked fasteners in back and side and of course they are rusted and stuck hard, will keep spraying them and hopefully get them freed up. Left side was pointing down by a lot, it did come up some with adjuster but something is screwed up with it. Right side is obviously disco from adjuster. Wish this car came from salt free zone. Will post with updates. Thank you.
 

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Nope, you gotta take the bumper off. It's not hard. Charles (Humble Mechanic) is an awesome resource for some DIYs. Sadly, he just got rid of his Passat. Great that he donated, it though.

The salt in these cases has nothing to do with the adjuster unless the rod that the plastic gear is fused to, rusted out.
 

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If it weren't for how the inside of the headlights are kind of tucked into the plastic support behind the grill.
 

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Discussion Starter #7
Those bolts are froze. The retainer or whatever the bolt threads in to moves but will not come loose, don’t want to break, strip.
98622
 

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Somewhere I saw repair kits (pre-kitted packages) with the 'barrel screw' that screws into the headlight assembly that jacks the headlight up or down and also the top and bottom mounting screws.
Can't find it now, of course.
 

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04 2.8 4motion wagon
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Discussion Starter #11
Thanks Andreas, I will look around for repair kit. I’m up in the air on which repair option. Want to look at it out of car and see if I can fix, get it to adjust. Probably broken. They are in ballpark currently, half ass adjusted on garage door. Nobody flashing me yet. Is that bolt that I took pictures of an adjuster in addition to the plastic adjuster?
 

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04 2.8 4motion wagon
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Discussion Starter #12
Maybe to get fixture to sit correctly and others for light?
 

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Got any Kroil? that stuff works wonders on those bolts.
 

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RockAuto has Hella replacement headlamp assemblies - if yours are in any way cloudy, it may just be best to go this route. They are $108 each. I used these Hellas to replace mine and have been very happy with them. The adjusters on mine were disconnected/broken/frozen when I bought my wagon in 2014. When I found the whole assemblies that reasonable on RA, I just decided to buy them and have it all working and new.
 

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Discussion Starter #15
Never heard of kroil, but I will look in to it. I have all the old school stuff. Thanks
 

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Discussion Starter #16
Thanks khnitz, if I go the replacement route I will check them out. That seems like great price for them. I have been trying to keep cost down on this rig, (since it’s just replacing my other winter beater) every time I fix something I find something else broke mostly due to human error of previous owner. Going to drive for a while to see how it does first. Although I did get it as part of someone’s divorce liquidation (free) Take care.
 

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Discussion Starter #18
Thanks Tortelious, that doesn’t exactly give me a warm feeling. My other winter rig is a 03 Jetta, paid $1800 7 1/2 years ago, now 220K, haven’t had very many issues outside of regular maintenance, this Passat is a different animal.
Khnitz, just looked at the headlights at RA, does the $107 have bulbs in it? What the hell could make the next one up jump to $285, gold plated?
 

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They did come with new bulbs, yes. The next higher one is for the version with the Xenon HID bulbs - maybe they include the ballast needed for those, too?
 

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Discussion Starter #20
I see, regular bulbs work for me. Thanks
 
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