I unscrewed the plastic housing to expose the 4 screws. I was able to crack one free, but the others would not budge. I thought I was going to burst a blood vessel in my face trying to turn that screwdriver as hard as I could. I was also worried I'd strip the screw. I gave up. I am fairly certain this is the original headlight and the screws are 15 years old.

Has anyone else encountered this? Should I use a phillips bit and try to use a breaker bar? This seems like a 2 man job. I don't see how PB blaster can do anything b/c only the screw head is exposed, and the screws are horizontal.

How am I supposed to get the screws loose? The odds of at least 1 screw out of the 4 getting stripped feels VERY high. Should I just pay a pro to install my headlight and harness upgrade?

 

Even though the screws are horizontal, using PB blaster or any other lubricant would be better than nothing. Just give it a good soaking and let it set and then go back and soak it again. You should be able to break them loose as long as you have patience and using the correct phillips bit. But if you cannot break them loose after a lot of cussing and fussing then drill the head of the screw off and use vise grips to unscrew the rest out. Oh and beer helps to calm the nerves. Haha

 

dremel a grove for a flatblade or dill out. Repalce wih stainless steel #8x1/2 machine screws

 

How do you use vice grips if you've just mangled off the screw's head? Without a screw head, it will now be flush with the bezel. What do you grab onto? And even if there was, I can't possibly see using a vice grip on a screw shaft being any easier than using a screwdriver. If the screwdriver can't budge it, I think there's no chance in hell a vice grip will do anything. It won't even grip it. Right?

Also, if you drill it out, won't you damage the screw holes? Then what ? Are you not able to screw anything there again? If so, I will have a headlight held on with 1 screw, since 3 are frozen solid. That sounds like a total hack job. If so, this sounds like work best left for a professional. I really don't want to hack up my XJ.

Why would dremeling a flatblade be any better? Is a flatblade groove easier to get out than Phillips? I already have TWO TWO grooves from the Philips. Do I cut a 3rd diagonal for that flatblade groove? Is that what you meant? I really don't see how this would work any better than the Phillips.

This is not encouraging.

 

after u use PB try tightening it bit first then loosen

 

You can PB it then try an impact driver to break it loose.

 

Remove bucket and all by unscrewing adjuster screws . Then you can work on it easier or hit Jy and replace if needed.

 

http://www.sears.com/craftsman-impac...1&blockType=G1
http://www.harborfreight.com/7-piece...set-93481.html
http://www.harborfreight.com/impact-...ase-37530.html

For $5, it's worth a try. Does this often strip the screw?
A possible problem is that the screw is deep back and recessed in the bezel/grille.
These sets seem to have a longer bit...

 

Mine were some variant of TORX.. But a smallish Phillips should work like everyone said. And yes,,, PB Blaster is your best friend man.

 

I am only talking about drilling just the head of the screw off now the whole screw. When you drill just the head off of each screw and then remove the bezel you will have enough left over of the screw to grip it with vice grips. You best friend will be the PB blaster, keep it lubricated and let it sit.

 

I know it sounds goofy but so many times if you have a bolt or nut that will not come loose if you tighten it just enough to where it just barely rotates. Then try to loosen it. Most times it will then break free easier. It will keep you from breaking bolts. I know it sounds retarded but it seems to break the thread tension.

 

Lol... I know this is of no help, but i just went through this.

I called my Dad to get those screws loose. He got it done.