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Author Topic: Headlight Range  (Read 6625 times)

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Lizzie Zoom

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Headlight Range
« on: 08 January 2023, 14:17:15 »

I have that annoying “Headlight Range” warning message showing, which stays on until I cancel it.

I have had this before on my other Omega’s, and know their is a device on one of the front suspension arms. 

On a 2003 3.2 what side is it on please?  Thinking how hard it may be to find a replacement part, can the old one be successfully cleaned up to make it work properly, or is it a case of hunting for a replacement please?  If so, has anyone got the part number for that device?

Many thanks. ;)
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Re: Headlight Range
« Reply #1 on: 08 January 2023, 14:23:39 »

Both front and rear left control arms.

The one in the rear right is for the air shocks.
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Lizzie Zoom

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Re: Headlight Range
« Reply #2 on: 08 January 2023, 15:05:32 »

Both front and rear left control arms.

The one in the rear right is for the air shocks.

Thanks :y
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Re: Headlight Range
« Reply #3 on: 08 January 2023, 20:16:17 »

Usually the plastic balljoint wears and comes apart. A good used replacement probably the best answer, but thin on the ground these days.
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dave the builder

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Re: Headlight Range
« Reply #4 on: 08 January 2023, 20:41:28 »

If you've got the BALLS and a stiff ROD you can make a new "arm"  :P
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Re: Headlight Range
« Reply #5 on: 08 January 2023, 20:42:30 »

If you've got the BALLS and a stiff ROD you can make a new "arm"  :P
Find an aged midget and pinch his hip replacement.
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Re: Headlight Range
« Reply #6 on: 08 January 2023, 20:44:29 »

If the lever on the sensor is still working, then a new link arm can be easily and cheaply made using generic ball and socket fittings.
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Re: Headlight Range
« Reply #7 on: 08 January 2023, 20:47:57 »

Or a UV resistant cable tie...
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dave the builder

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Re: Headlight Range
« Reply #8 on: 08 January 2023, 20:54:12 »

If you've got the BALLS and a stiff ROD you can make a new "arm"  :P
Find an aged midget and pinch his hip replacement.
;D
Opti  will be along shortly (probably tomorrow now, it's past his bedtime), to say you can't call them "midgets"  :o
though I genuinely can't think what the woke /PC term is  :-[
Also "pinch" is theft , and has been frowned upon since Moses's time, when he downloaded rules onto his ipad tablet  :-X

If the lever on the sensor is still working, then a new link arm can be easily and cheaply made using generic ball and socket fittings.
that's what I said here >>>>

If you've got the BALLS and a stiff ROD you can make a new "arm"  :P

Or a UV resistant cable tie...

I did a temporary fix 5 years ago to my front one with 3 cable ties  :)
must get around to a permanent fix one day  :D
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Re: Headlight Range
« Reply #9 on: 09 January 2023, 17:33:31 »

If you've got the BALLS and a stiff ROD you can make a new "arm"  :P

Thanks Dave and Nick, I like that line of thought! :y :y

I also like the cable ties idea DG! :)

I am about to find out what condition the existing unit is in, then make decisions.

Does anyone know what the original Vx part number was for this device just in case I can obtain a new one on the web?

Thanks all :y :y
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Re: Headlight Range
« Reply #10 on: 09 January 2023, 18:02:54 »


Does anyone know what the original Vx part number was for this device just in case I can obtain a new one on the web?

Thanks all :y :y
just google hens teeth from the saddle bag of a triple headed unicorn  :y

OR

fix the one you have if possible  :)

or buy another omega with working level control and hope the sensor is worth salvaging  :P
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Re: Headlight Range
« Reply #11 on: 09 January 2023, 18:31:37 »


Does anyone know what the original Vx part number was for this device just in case I can obtain a new one on the web?

Thanks all :y :y
just google hens teeth from the saddle bag of a triple headed unicorn  :y

OR

fix the one you have if possible  :)

or buy another omega with working level control and hope the sensor is able to be salvaged :P
Fixed.

Given the propensity of not being prepared to keep it tip top at any cost, you may be better accepting that it doesn't work. The original sensors were unavailable fifteen years ago and the Vectra C ones that superceded them aren't plug and play and are thin on the ground even second hand as almost no Vectra Cs had xenon lights fitted.
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Re: Headlight Range
« Reply #12 on: 10 January 2023, 12:00:21 »

I think I chucked the one I had on the shelf only just before Xmas.  Its possible its still in the bin in the garage.


2 usual modes of failure:
Balljoint issues - fixable in a variety of ways, as previously described.
Water ingress - its got quite complex electronics in, considering what it does.  Hard to get them apart without breaking them, and resealing the case afterwards could be a problem.  Never tried repairing one thats had water ingress, but I doubt it'll just dry fully with a hairdryer ;D
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Re: Headlight Range
« Reply #13 on: 10 January 2023, 16:07:58 »

I have that annoying “Headlight Range” warning message showing, which stays on until I cancel it.

I have had this before on my other Omega’s, and know their is a device on one of the front suspension arms. 



On a 2003 3.2 what side is it on please?  Thinking how hard it may be to find a replacement part, can the old one be successfully cleaned up to make it work properly, or is it a case of hunting for a replacement please?  If so, has anyone got the part number for that device?

Many thanks. ;)

In answer to your actual question Lizzie - it is highly likely to be the ball joints on the rod that have seized, rather than the sensor failing. I have successfully cleaned up, lubricated and reused the rod from my existing ones previously. They need removing from the car, lubricating, and very gently work each balljoint gently until its movement is acceptable without force.
The headlight level and suspension level sensors originally were the same part number - 9117094, but this NLS. However the respective the part numbers have been replaced by 93197245 (headlight) and 93197514 (suspension). The rod is part number 9117095 which hasnt been superceeded.
Availability though, may be the difficulty.
When Omega were relatively common in breakers, I removed good arms just for spares, which is your last option, but they are just as likely to in the condition yours are at present.. I'm however certain you will be able to resurrect your own with care.
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Re: Headlight Range
« Reply #14 on: 10 January 2023, 17:37:25 »

as i once asked a while back ( cant remember the reply )
if the arm comes off why does it throw up afault ?surely thats just like a non moving car ?
 is the shaft then free to move to its extreme end or spring loaded ?
when i got my omega one arm was detached and allthat happened was the lights didnt move when you loaded the boot. arm back on and they moved again !
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Re: Headlight Range
« Reply #15 on: 10 January 2023, 17:58:33 »

The HID suspension sensors and the self levelling suspension sensor/ecu are not the same part or interchangeable.

The HID ECU has a trivial time of working out if the sensor has moved or not, so car easily work out if the signal is plausible.
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Re: Headlight Range
« Reply #16 on: 10 January 2023, 18:06:43 »

I’ve had headlight position warning on since I bought the car I ignore it as my lights appear to be ok anyway😎
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Re: Headlight Range
« Reply #17 on: 10 January 2023, 18:10:33 »

I’ve had headlight position warning on since I bought the car I ignore it as my lights appear to be ok anyway😎
If the headlight motors are working, it lowers to lowest position for safety (of other road users).  Nothing to stop people raising them manually, but its a bit idiottish, like resetting headlights after every MOT, because sod you jack, I'm OK.
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Re: Headlight Range
« Reply #18 on: 10 January 2023, 18:13:39 »

Both the suspension level sensor/control module and headlight levelling control module (two completely independent systems) have a speed signal feed from the ABS. The diagnostic process probably doesn't complete until the car moves. At which point a constant signal from one sensor vs a dynamic signal from the other will trigger the fault warning.
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Re: Headlight Range
« Reply #19 on: 10 January 2023, 19:04:09 »

The HID suspension sensors and the self levelling suspension sensor/ecu are not the same part or interchangeable.



It's also very easy to damage them when trying to remove them - the mounting nuts rust in place, and you break the plastic. This means you've disabled an important mechanical and useful feature to diagnose a lesser one.
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Re: Headlight Range
« Reply #20 on: 10 January 2023, 19:16:39 »

theres a green elite breaking on ebay mrs zoom.
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Re: Headlight Range
« Reply #21 on: 10 January 2023, 19:23:27 »

2 pages to this thread so far ,all good advice but unless Lizzie actually looks at the sensor to see what's wrong  :-X
pretty sure the forum posts and software can't do that for her  :D
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Re: Headlight Range
« Reply #22 on: 10 January 2023, 19:40:41 »

The arm on the sensor bracket isn't spring loaded Chris - it just adopts whatever position the wishbone or rear swinging arm causes it to be in!
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Re: Headlight Range
« Reply #23 on: 10 January 2023, 19:41:37 »

Until it gets smacked by the wishbone when you hit a pothole.
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Re: Headlight Range
« Reply #24 on: 10 January 2023, 20:37:29 »

The HID suspension sensors and the self levelling suspension sensor/ecu are not the same part or interchangeable


Yes, you are correct - my error in describing the rear headlight level sensor on the rear nearside suspension arm as suspension level sensor, rather than head light level sensor.
But the front and rear headlight level sensors are both the same part numbers I quoted - the superceded part numbers for are different for the two - not sure why really but there we go....
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Re: Headlight Range
« Reply #25 on: 10 January 2023, 20:45:04 »

The arm on the sensor bracket isn't spring loaded Chris - it just adopts whatever position the wishbone or rear swinging arm causes it to be in!


thanks.
maybee mine (although working fine) does have a slight fault anyway . it never had any error message when the car was bought but the lights didnt move .arm was off.
putting the arm back on made them work again.its been mentioned that the ecu looks for movement signals that suggest the car is driving. and i suppose that unkess we found a road that was as smooth as glass it would alwaysdetect this ?
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Re: Headlight Range
« Reply #26 on: 10 January 2023, 21:35:37 »

The HID suspension sensors and the self levelling suspension sensor/ecu are not the same part or interchangeable


Yes, you are correct - my error in describing the rear headlight level sensor on the rear nearside suspension arm as suspension level sensor, rather than head light level sensor.
But the front and rear headlight level sensors are both the same part numbers I quoted - the superceded part numbers for are different for the two - not sure why really but there we go....
It’s because the Vectra C platform from which they come has a very different rear suspension arrangement to the Omega ;)
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Re: Headlight Range
« Reply #27 on: 10 January 2023, 21:38:32 »

The xenon ecu is about the same size as the engine one, whereas the level control 'ecu' is the ride height sensor itself.
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Lizzie Zoom

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Re: Headlight Range
« Reply #28 on: 11 January 2023, 09:16:52 »

I have that annoying “Headlight Range” warning message showing, which stays on until I cancel it.

I have had this before on my other Omega’s, and know their is a device on one of the front suspension arms. 



On a 2003 3.2 what side is it on please?  Thinking how hard it may be to find a replacement part, can the old one be successfully cleaned up to make it work properly, or is it a case of hunting for a replacement please?  If so, has anyone got the part number for that device?

Many thanks. ;)

In answer to your actual question Lizzie - it is highly likely to be the ball joints on the rod that have seized, rather than the sensor failing. I have successfully cleaned up, lubricated and reused the rod from my existing ones previously. They need removing from the car, lubricating, and very gently work each balljoint gently until its movement is acceptable without force.
The headlight level and suspension level sensors originally were the same part number - 9117094, but this NLS. However the respective the part numbers have been replaced by 93197245 (headlight) and 93197514 (suspension). The rod is part number 9117095 which hasnt been superceeded.
Availability though, may be the difficulty.
When Omega were relatively common in breakers, I removed good arms just for spares, which is your last option, but they are just as likely to in the condition yours are at present.. I'm however certain you will be able to resurrect your own with care.

Thanks Jonnydog, that info is very useful. :y :y

The rain has for the moment stopped falling here so I am going to get the wheels off and investigate properly  :)
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Re: Headlight Range
« Reply #29 on: 11 January 2023, 09:19:23 »

I’ve had headlight position warning on since I bought the car I ignore it as my lights appear to be ok anyway😎

But mine is due an MOT, so would this not amount to a “Failure” ?  How did you get around that please? ???
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Re: Headlight Range
« Reply #30 on: 11 January 2023, 09:22:06 »

2 pages to this thread so far ,all good advice but unless Lizzie actually looks at the sensor to see what's wrong  :-X
pretty sure the forum posts and software can't do that for her  :D

Indeed Dave, and today, now all the heavy rain has stopped falling, I can indeed go for that inspection :D ;)
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Re: Headlight Range
« Reply #31 on: 11 January 2023, 09:24:20 »

Until it gets smacked by the wishbone when you hit a pothole.

Yes, I have managed to hit two bad ones recently due to the awful state of our local roads DG.  Fxxking potholes everywhere!! >:(
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Re: Headlight Range
« Reply #32 on: 11 January 2023, 10:34:16 »

....

Yes, I have managed to hit two bad ones recently due to the awful state of our local roads DG.  Fxxking potholes everywhere!! >:(

That's not like you Lizzie!  ??? ;D ;D
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Re: Headlight Range
« Reply #33 on: 11 January 2023, 12:04:53 »

....

Yes, I have managed to hit two bad ones recently due to the awful state of our local roads DG.  Fxxking potholes everywhere!! >:(

That's not like you Lizzie!  ??? ;D ;D

Oh yes Andy, sometimes even I can see red, and the issues of potholes around Ashford is now scandalous and makes me utter four letter words!! ::) ;D ;)
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Re: Headlight Range
« Reply #34 on: 11 January 2023, 12:21:11 »

Well now I am confused................maybe not unusual now given my increasing age!!......but yes I am!

I have removed all four wheels and inspected the area surrounding the suspension struts and arms.  But all I found was as in the following picture (after I had soaked the device with WD40), which was on the suspension arm of the rear offside.  It is nothing like the device I used to find, and once replaced, on previous Omega's.


The arms and joints of this device were all intact and are an improvement on the ones previously seen, although it is still so exposed.

So, what does this change with a 2003 3.2 miggy mean?  What am I missing. Is this one device the issue that must be resolved, or is there another device hidden elsewhere please?
« Last Edit: 11 January 2023, 12:24:01 by Lizzie Zoom »
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Re: Headlight Range
« Reply #35 on: 11 January 2023, 12:51:32 »

Well now I am confused................maybe not unusual now given my increasing age!!......but yes I am!

I have removed all four wheels and inspected the area surrounding the suspension struts and arms.  But all I found was as in the following picture (after I had soaked the device with WD40), which was on the suspension arm of the rear offside.  It is nothing like the device I used to find, and once replaced, on previous Omega's.


The arms and joints of this device were all intact and are an improvement on the ones previously seen, although it is still so exposed.

So, what does this change with a 2003 3.2 miggy mean?  What am I missing. Is this one device the issue that must be resolved, or is there another device hidden elsewhere please?

99% of the time it's the front sensor on the wishbone, no the rear one pictured
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Re: Headlight Range
« Reply #36 on: 11 January 2023, 13:34:23 »

Well now I am confused................maybe not unusual now given my increasing age!!......but yes I am!

I have removed all four wheels and inspected the area surrounding the suspension struts and arms.  But all I found was as in the following picture (after I had soaked the device with WD40), which was on the suspension arm of the rear offside.  It is nothing like the device I used to find, and once replaced, on previous Omega's.


The arms and joints of this device were all intact and are an improvement on the ones previously seen, although it is still so exposed.

So, what does this change with a 2003 3.2 miggy mean?  What am I missing. Is this one device the issue that must be resolved, or is there another device hidden elsewhere please?

99% of the time it's the front sensor on the wishbone, no the rear one pictured

Thanks, but I could not find one on the front or rear wishbones. :o :o

I do not know what to do now.  Has anyone got a picture of one on a 2003 3.2 please? ??? ???
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Re: Headlight Range
« Reply #37 on: 11 January 2023, 14:01:41 »

The headlight sensor is on the front, near-side wishbone, close to the rear bush. It looks like the one in your pic, but with a shorter lever arm. If the droplink between the arm and the wishbone is missing, it's much harder to see. And that would definitely create the warning you have.
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Re: Headlight Range
« Reply #38 on: 11 January 2023, 14:19:37 »

The headlight sensor is on the front, near-side wishbone, close to the rear bush. It looks like the one in your pic, but with a shorter lever arm. If the droplink between the arm and the wishbone is missing, it's much harder to see. And that would definitely create the warning you have.

Thanks Nick! :-* :y

I did look there, but I will go outside again now, before the rain comes again, and reinspect.  It is where the previous Omega's had the device, so I must try harder to see it!! ::) ;D ;D ;D ;)
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Re: Headlight Range
« Reply #39 on: 11 January 2023, 15:41:00 »

Yes, YES!!!  Thanks again Nick!! :y :y

Found it, but not in the place it was on previous Omega's.  It was set well back behind the suspensions strut and partially mounted on the chassis with the link on the wishbone.  There it was, the bottom of the lever floating in the air, separated from the wishbone fixing.

This is how it is now, although I have since removed the ends of the cable ties, after taking the advice of DG and Dave, with cable ties that I have always a stock of due to my electrical work:



Should work.  It certainly has got rid of the advisory message! :D :D :y :y
« Last Edit: 11 January 2023, 15:44:47 by Lizzie Zoom »
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Re: Headlight Range
« Reply #40 on: 11 January 2023, 16:23:56 »

That first picture is the rear suspension level sensor/ecu :y
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Re: Headlight Range
« Reply #41 on: 11 January 2023, 16:44:08 »

That first picture is the rear suspension level sensor/ecu :y

Thanks DG, that explains a lot.  Never noticed that sensor before. :-[ :D ;)
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Re: Headlight Range
« Reply #42 on: 11 January 2023, 16:47:09 »

Yes, YES!!!  Thanks again Nick!! :y :y

Found it, but not in the place it was on previous Omega's.  It was set well back behind the suspensions strut and partially mounted on the chassis with the link on the wishbone.  There it was, the bottom of the lever floating in the air, separated from the wishbone fixing.

This is how it is now, although I have since removed the ends of the cable ties, after taking the advice of DG and Dave, with cable ties that I have always a stock of due to my electrical work:



Should work.  It certainly has got rid of the advisory message! :D :D :y :y

Reason the arm had popped out is obvious - the ball joint is bone dry - needed some grease on it, because it is dry it will have worn the joint so will always need tie wraps to keep it on.


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Re: Headlight Range
« Reply #43 on: 11 January 2023, 17:10:01 »

if the ball is intact and the hole / edges are intact a sheet of plastic over the ball is usually enough to restore rigidity. greased up obviously.
worked on a mates vectra taxi where the wiper linkage regularly fell off !
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Re: Headlight Range
« Reply #44 on: 11 January 2023, 18:34:47 »

2 pages to this thread so far ,all good advice but unless Lizzie actually looks at the sensor to see what's wrong  :-X
pretty sure the forum posts and software can't do that for her  :D
Yeah, common Love, pull yer finger out!

;D
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Re: Headlight Range
« Reply #45 on: 11 January 2023, 18:41:07 »

Oops, should have read the whole thread.

LZ - as DG says, the first pic is the suspension level sensor (only fitted to Elites).  You have now found the correct ones, they are fitted in the same place on all Omegas fitted with HIDs (MFL MV6 and Elites, and FL MV6, CDX and Elites).

If your "fix" doesn't work long term, it should be possible to fabricate a new rod and ball joints.  And now you know which sensor and where it is, that makes life easier.
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Re: Headlight Range
« Reply #46 on: 11 January 2023, 18:59:15 »

Oops, should have read the whole thread.

LZ - as DG says, the first pic is the suspension level sensor (only fitted to Elites).  You have now found the correct ones, they are fitted in the same place on all Omegas fitted with HIDs (MFL MV6 and Elites, and FL MV6, CDX and Elites).

If your "fix" doesn't work long term, it should be possible to fabricate a new rod and ball joints.  And now you know which sensor and where it is, that makes life easier.

Indeed TB, although I hope my “repair” will last long enough for me not to revisit this ::) ;D ;D ;)

But yes, due to the advice, I can see what I could do for a more permanent fix  :)
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Re: Headlight Range
« Reply #47 on: 11 January 2023, 21:59:19 »


Indeed TB, although I hope my “repair” will last long enough for me not to revisit this ::) ;D ;D ;)

But yes, due to the advice, I can see what I could do for a more permanent fix  :)


I have the bits - ballstuds, plastic housings and LH/RH threaded rod - to make a new droplink if you're interested.
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Re: Headlight Range
« Reply #48 on: 12 January 2023, 00:09:47 »

I’ve had headlight position warning on since I bought the car I ignore it as my lights appear to be ok anyway😎

But mine is due an MOT, so would this not amount to a “Failure” ?  How did you get around that please? ???
                Sorry Lizz missed that, my mot guy has a dodgy eye on times👀👀🤭
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Re: Headlight Range
« Reply #49 on: 12 January 2023, 09:05:09 »

I’ve had headlight position warning on since I bought the car I ignore it as my lights appear to be ok anyway😎

But mine is due an MOT, so would this not amount to a “Failure” ?  How did you get around that please? ???
                Sorry Lizz missed that, my mot guy has a dodgy eye on times👀👀🤭


Because without a working sensor the headlights won't move. Which in turn means you can adjust them to pass an MOT**


** the MOT requirement is that they don't blind oncoming traffic, not that you can see where you going, so tweaking them down and to the left is usually good enough.
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Re: Headlight Range
« Reply #50 on: 12 January 2023, 10:10:14 »

Aren't any MOTers now shitty on dash lights (granted on an Omega, the warning isn't on the dash binnacle)?
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Re: Headlight Range
« Reply #51 on: 12 January 2023, 11:14:55 »


Indeed TB, although I hope my “repair” will last long enough for me not to revisit this ::) ;D ;D ;)  :-*

But yes, due to the advice, I can see what I could do for a more permanent fix  :)


I have the bits - ballstuds, plastic housings and LH/RH threaded rod - to make a new droplink if you're interested.

Yes please Nick :y :y

The part that is faulty is the fixing on the wishbone, and I suppose the drop link that must be worn.  But you know what I will need, thanks.

Please let me know how much I must send you and I will give you my address via PM. :-* :-*
« Last Edit: 12 January 2023, 11:21:56 by Lizzie Zoom »
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Re: Headlight Range
« Reply #52 on: 12 January 2023, 11:16:36 »

I’ve had headlight position warning on since I bought the car I ignore it as my lights appear to be ok anyway😎

But mine is due an MOT, so would this not amount to a “Failure” ?  How did you get around that please? ???
                Sorry Lizz missed that, my mot guy has a dodgy eye on times👀👀🤭


Because without a working sensor the headlights won't move. Which in turn means you can adjust them to pass an MOT**


** the MOT requirement is that they don't blind oncoming traffic, not that you can see where you going, so tweaking them down and to the left is usually good enough.

Thanks Raeturbo and Nick, now I understand. :y :y
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Re: Headlight Range
« Reply #53 on: 12 January 2023, 12:55:15 »

I was lucky enough to have had my headlight positioning paraphernalia fail in a range where the lights are not too high and not too low :y
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