Help! I've messed up my headlight aiming servos. (2000 Astra)

Hi folks,

A few days ago, the bulbs for the dipped headlights in my 2000 Astra both
blew. I bought replacement bulbs from Halfords and attempted to fit them
myself.

I made a mistake initially. Instead of removing the plastic socket for the
headlight bulb, I removed the aiming servo (it was getting dark and I
couldn't see what I was doing properly).

The aiming servo has a rod extending from it, with a ball on the end which
clips into a socket on the back of the reflector
(http://www.b0rken.org/~jason/aiming_servo.jpg 61kb). When I put the servo
back in, the ball did not clip back into the socket as it seems to be too
stiff. Instead, it just sits outside the socket, pushing the bottom of the
reflector forwards and pointing the headlight beam way too high, dazzling
other drivers.

If I could somehow brace the reflector, I could make sure the ball clips
back into the socket properly, but I can't get access to it.

Has anyone else here fiddled with the headlight assembly on an Astra (or
similar) and had this problem? How did you resolve it?

Many thanks.

Jason

 

The bit the ball goes into is a slot. If you put the motor in at an angle
it will slide back in. Use a mirror to see where you need to be.

 

you will find it easier if you remove the headlamp, it doesnt take long,
once you have, remove the headlamp bulb so you can grip the lens with one
hand and gently persuade the ball joint back into place with the other, a
little grease will help, but you may need to be quite firm with it, use the
manual adjuster to extend the rod to its maximum to give you more room to
pop it on.
tricky, but not impossible.
you will need to have the headlamps re-aligned once you have finished,
nothing worse than a car behind blinding you with headlamps too high...

 

Thank you both for your suggestions. I managed to fix the problem using your
advice.

Jason