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Old 06-28-2010, 12:00 PM   #1 (permalink)
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Default Broken retainer clip- headlamp replacement

I really screwed the pooch on this one. In order to remove the headlamp bulb you have to take off the rubber socket cover, and unplug the lead going to the electrical system. Then there is a plastic adapter which plugs into the bulb, and both are held in place with a wire clip that attaches to a gray plastic piece in the headlight assembly.

The gray plastic piece is held on with a screw, and looks like it is designed to easily come off. What I did, was break the gray plastic piece where the wire clip was held on/articulate. Now I have no way to hold the bulb and adapter in place!

Any suggestions? I went to the dealer and they did not have that piece listed separately... only the socket cover, adapter, grommet for the high beam, and the whole headlight assembly for US$300+.

I've attached the page from the FSM with the part in question circled. Can one of you GV-Geniuses help me find the part I need, or perhaps suggest an atlernative method for holding the pieces in place?

Thank you so much!
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Broken retainer clip- headlamp replacement-brokenpiece.png  
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Old 07-02-2010, 12:10 AM   #2 (permalink)
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Crappy design, not your fault....
I've made the same error a year ago, but did not want to spend time or money on replacement and simply attached the thing back and fastened with a piece of rubber string. Still works.
The mechanic at Suzuki looked at it and told me to go to the junk yard and pull the whole headlight off. They do not sell the part, only the whole headlight assembly and it is costly. So far I am Ok with the string :-)
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Old 07-02-2010, 06:33 PM   #3 (permalink)
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First response would be, find a salvage yard with a GV that has busted headlights. They can't sell them as whole units, but the part you need is probably OK.

In the meantime (or instead of, depends) you might try a few things. I'm not sure exactly what broke...if it's the piece that holds the wire clip in place, you might be able to do something with a washer (I did that, had to grind one side flat so it fit properly, but it works better than the original piece). If the problem is with the piece the screw threads into, you can maybe drill it deeper and use a longer screw, or maybe oversize it and use a larger screw. If need be, pick up some industrial epoxy rebuild material and use that (or there are some materials made specifically for repairing/rebuilding plastic parts--I've seen them advertised for motorcycle fairing repairs, etc).

I'm sure it is repairable--most things are!
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Old 10-19-2010, 03:47 PM   #4 (permalink)
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I've used epoxy, JB Weld, etc. on my Jeep plenty of times. The GV engine compartment is way more cramped to work in than what I'm accustomed to on the ZJ. I have big, meaty rhinoceros hands to boot...

So in the end, a Nylon zip-tie did the job nicely. I used a curved locking hemostat to feed the pointy end in to the perforations around the ring of the bulb retainer, and a pair of needle-nose pliers to gently pull it across the opening, and the hemostat again to pull it through the perforations on the other side, and locked it to keep it from fallign back through. Put the bulb in, ratcheted the zip down and cut the dangly bit off. Holds the bulb in firmly and does not interfere with the light at all.

Sometimes the simplest ways are the best ways.
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Old 10-23-2010, 03:51 PM   #5 (permalink)
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mine broke a few years ago not on the screw side the other side. i took the wire out un bent it and reshaped it so it puts pressure on the back of the houseing, i just pull it and it swings open like it used to it just holds form a different place and i can still easilly change the bulb, which i think tend to burn out fast, (3rd set since 2006). i broke mine on the drivers side wonder if every one else did the same.
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Old 10-23-2010, 07:32 PM   #6 (permalink)
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Quote:
Originally Posted by fred79 View Post
...easilly change the bulb, which i think tend to burn out fast, (3rd set since 2006).
We've never burned out any bulb on our GV, which is nearly 5 years old. Odd that there would be this great a difference in burnout rates.
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Old 10-24-2010, 11:09 AM   #7 (permalink)
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Quote:
Originally Posted by geevee View Post
We've never burned out any bulb on our GV, which is nearly 5 years old. Odd that there would be this great a difference in burnout rates.
You're quite lucky then. Those H7 bulbs burn out all the time in GVs
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Old 11-02-2010, 02:46 PM   #8 (permalink)
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Where did you get this diagram? I just broke the wire clip and have it secured with a zip tie but I cant get it adjusted properly.
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Old 11-27-2010, 05:48 PM   #9 (permalink)
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My GV left/front headlight bulb gave up the spirit this morning as I drove back home from work. Got a pair replacement. I don't have the maintenance book on my car, so decided to cruise and search the net for a way to do so, and ran into this forum. Thanks for letting us know about the possibility of braking the plastic tab spring retainer . I did print you image in regards to the parts id and location. I went ahead and loosened the small philipps screw that holds the clip and puts pressure on it. It took about two turns (didn't want to loosen completely, falling unto the engine compartment abyss below), enough to release pressure on the spring. Once done with that, I tied a small string to the spring (an improvised lanyard) to keep it from disappearing into oblivion, and used a small flat screwdriver and "popped" the spring from under the small screw. It came out fine. Trying to get the new bulb back into place was the real challenge. I guess the designer of this light set up was a Japanese engineer female with very small hands. Anyways, thanks to this forum, I was able to avoid the headaches you guys and gals went thru. Tomorrow I will replace the right/front bulb using the same procedure.
I need to "spice up" my 2006 Sports GV. I love my full hard spare tire cover. It gives it a nicer look than the new ones coming out of the factory.
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Old 01-12-2012, 10:03 PM   #10 (permalink)
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Quote:
Originally Posted by Jeff L. View Post
You're quite lucky then. Those H7 bulbs burn out all the time in GVs
Well, after 6 years, our GV has finally burned out a bulb. An H7 low beam headlight, of course. I've copied pmccarty's instructions from another topic:
http://www.suzuki-forums.com/2g-2006...ht-bulb-2.html

"I have changed the low beam headlights 3 times for 37k miles on my 2006 GV. They are hard to reach, but the easiest way for me is to unplug the wire, pull the rubber boot off (start with a corner and push it off rather than pulling on it...very tight fit). Pull the plug off the bulb. The rubber boot hugs the plug very tight. There is a clamp holding the existing bulb and you have to press the clamp toward the lens to get it unhooked. Then replace the bulb and press the clamp back on the bulb to hold it in place. Now the hard part is getting it all back together. First, I remove the plug from the rubber boot...just pull it out slowly. Then I put the plug on the bulb securely. Then apply a little bulb grease to the inside of the rubber boot and slide it back over the plug and slide the outside of the boot over the bulb housing. Now you can plug the wire back onto the plug. I used to try an re-connect the plug with the rubber boot attached and that just does not work...I could never get the plug aligned on the bulb. "
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