95 Zenki HID Retrofit Question - Zilvia.net Forums | Nissan 240SX (Silvia) and Z (Fairlady) Car Forum

ADIDASilvias · 04-27-2015, 10:42 AM

Hola Zilvians!

I am in the process of retrofitting my Zenki headlights with FX35 projectors via the guide by greenkouki on HIDplanet.

A couple pointers for anyone doing this in the future. To separate the old lenses from the housing, bake them in the oven at 250 degrees for 12-15 minutes. The first guide I followed said 6 minutes, but all that did was cause me to mar up the edge of the housing because I had to pry all over the place. Plus it cooled too quickly and I had to keep putting the headlight back in the oven to keep the butyl sticky.

12-15 minutes was long enough to get the butyl soft enough to pry in a couple places and then grab both the lens and housing and physically pull them apart.

Now to my questions. I got the adjustment screws for the reflectors backed all the way out. My adjustment gears for the side to side adjuster were stripped and I had to remove the small white cover over the gears and use a pair of vice grips to back that side out.

Is there anywhere I can buy replacement gears? I thought I'd check Mcmaster-Carr and see if I can match the gear sizes and replace them with metal gears so it never strips again, but if I can buy stock replacement gears I might go that route since I wouldn't have to rig it to work.

I checked online and none of the diagrams show these parts, so I assume they just expect you to replace the entire housing. Unless I am missing it somewhere.

Also, there is a pivot ball joint that attaches the reflector to the housing, and I cannot for the life of me get the joint to pop loose to remove the reflector. You can't remove both screws on the attachment point since one is hidden by the reflector.

Any tips for getting this loose? I don't want to pull too hard for fear of breaking something.

04-27-2015, 10:42 AM	#1
ADIDASilvias Leaky Injector Join Date: Jul 2014 Location: Colorado Posts: 122 Trader Rating: (0) Feedback Score: 0 reviews	95 Zenki HID Retrofit Question Hola Zilvians! I am in the process of retrofitting my Zenki headlights with FX35 projectors via the guide by greenkouki on HIDplanet. A couple pointers for anyone doing this in the future. To separate the old lenses from the housing, bake them in the oven at 250 degrees for 12-15 minutes. The first guide I followed said 6 minutes, but all that did was cause me to mar up the edge of the housing because I had to pry all over the place. Plus it cooled too quickly and I had to keep putting the headlight back in the oven to keep the butyl sticky. 12-15 minutes was long enough to get the butyl soft enough to pry in a couple places and then grab both the lens and housing and physically pull them apart. Now to my questions. I got the adjustment screws for the reflectors backed all the way out. My adjustment gears for the side to side adjuster were stripped and I had to remove the small white cover over the gears and use a pair of vice grips to back that side out. Is there anywhere I can buy replacement gears? I thought I'd check Mcmaster-Carr and see if I can match the gear sizes and replace them with metal gears so it never strips again, but if I can buy stock replacement gears I might go that route since I wouldn't have to rig it to work. I checked online and none of the diagrams show these parts, so I assume they just expect you to replace the entire housing. Unless I am missing it somewhere. Also, there is a pivot ball joint that attaches the reflector to the housing, and I cannot for the life of me get the joint to pop loose to remove the reflector. You can't remove both screws on the attachment point since one is hidden by the reflector. Any tips for getting this loose? I don't want to pull too hard for fear of breaking something.