Member Since: 02 Jan 2005
Location: A bit there, a bit over there and sometime at home, France
Posts: 1006
Headlamp opening and modification in photos
Hey Disco lovers
As some of you seem to have interest in that modification, especially state side, and as it seems no one has ever posted how to do so, here is how to open and modify your Discovery 3 headamps, may they be Xenon or Halogen
Note 1 : I did this myself so you should be able to do so too. If you break you headlamp or anything else in the process following this guide, your bad.
First you need the take the whole unit out. Grab an adequate spanner en gently pull up the tabs in order to take the unit out.
On a clean, flat area, lay a soft cloth, or padding as you will need to get the clear cover face down and apply pressure along the process
Take the bracket out by unscrewing the 7 silver bolts then the 4 small black bolts (both types are Philips)
Take the bracket aside, away from where you are working and make sure to put all the screws in a closed container.
For the next step, some may use the oven technique, I prefer the hair dryer one.
On the first you put the headlamp in an oven à 200° f / 90 °C for 3 minutes once it is hot.
On the hair drying, you blow hot air evenly on the surroundings of the headlamp, where the black body and clear cover meet.
They are held together by black glue and clips.
As you warm the unit, the clips start to become soft and soon you are able to unclip them.
Do NOT use brute force, blow for 10 minutes before starting anything. Don’t even try to unclip without warming it. Hold the hair dry close to the headlamp, but avoid contact.
After another 5 minute of heating the glue, take the clear cover away from the body using the bracket built in the clear cover in order to get a good grip (they are on the side of the headlamp that is by the grill of the Disco).
To get similar grip on the black body, unscrew all bulb access caps from it, giving you hole to put your fingers in.
While you are at it, unplug the blinker (1/4 turn) and lower light bulb (just pull on this one)
Go slowly, take your time.
Go slowly, don’t break it !
As you start to get the clear part off, continue to warm evenly (a second person would really help here)
Go slowly, be gentle.
Until the 2 parts are apart, go slow and heat them up.
Be careful at the end as the blinkers and lower light might still be attached to the chrome part itself held with the clear part.
Put the clear cover/chrome bits on your padded area and unscrew the chrome part.
Unscrew only the outer screw (the silver ones) not the inside ones (copper ones)
Gently pull away the chrome trim
Unscrew the amber bit. unclip it.
Note 1 : I still have to figure a way to replace the thin amber reflective strip. I will try to take it off tomorw
Note 2 : the chrome trim is in fact 4 pieces either screwed or cliped together : one large pieces around the main beam, one that is covered by the whole amber trim, one for the blinker bowl itself then a tiny one in the lower sidelight one (not for adaptive headlamps as they have a bulb instead)
Note 3 : for USA and other markets, there is a side light that sticks out under the amber trim, on the middle of the reflective strip. You guys may figure a way to alter it or simply glue the amber reflective strip.
Voilà !
To install, reverse the removal procedure. Use pressure while the headlamp cool off (strap or clamps)
One may paint it body color or contrasting color, one may leave it chrome with Philips Silver Vision blinker bulbs (I am), some may put LEDs, à la Disco4 and Audi R8… (I checked and you can not put LED or LED strip where you would want to put them to make it all look like a disco4 one, sorry updaters ! 8) )
Do what you like, don’t pimp it all too much please though !
Please check out my other post about this, participate to it and check many more photos here :
http://www.disco3.co.uk/forum/topic36262.html
l=Oo\________/oO=l l:Ool======loO:l
Current
RANGE ROVER Vogue 4.4L TDV8 - 2012 - Orkney Grey, on Black, on Piano Black.
RANGE ROVER Vogue 4.4L V8 - 2002 - ex-2003 G4 Challenge Event Vehicle, Stage 3: Australia
FREELANDER 2 Td4 HSE "000" - Santorinin Black on Black
Gap Diagnostics' Classic and BT IID Tools!
Previous:
RANGE ROVER TDV8 x3
RANGE ROVER Td6 x1
RANGE ROVER Classic 3.5L V8 x1
DISCOVERY III x3
DISCOVERY II x3
DISCOVERY I x4
Last edited by Verydisco on 23rd Jun 2009 9:12 am. Edited 2 times in total
22nd Jun 2009 9:27 pm
tanters
Member Since: 24 Oct 2007
Location: Oireland
Posts: 4287
Good work
ThanksA happy childhood ... is the worst possible preparation for life.
22nd Jun 2009 9:50 pm
Verydisco
Member Since: 02 Jan 2005
Location: A bit there, a bit over there and sometime at home, France
Posts: 1006
tanters wrote:
Good work
Merci Tanters.
Just giving back a small bit that this site gave me
PS: now you know why I crave the extra grill ... l=Oo\________/oO=l l:Ool======loO:l
Current
RANGE ROVER Vogue 4.4L TDV8 - 2012 - Orkney Grey, on Black, on Piano Black.
RANGE ROVER Vogue 4.4L V8 - 2002 - ex-2003 G4 Challenge Event Vehicle, Stage 3: Australia
FREELANDER 2 Td4 HSE "000" - Santorinin Black on Black
Gap Diagnostics' Classic and BT IID Tools!
Previous:
RANGE ROVER TDV8 x3
RANGE ROVER Td6 x1
RANGE ROVER Classic 3.5L V8 x1
DISCOVERY III x3
DISCOVERY II x3
DISCOVERY I x4
22nd Jun 2009 9:55 pm
DG Site Moderator
Member Since: 12 Dec 2005
Location: The Gaff
Posts: 50978
Great stuff.
I have to ask... how secure and watertight are they when you have put them back together ??21 year LR veteran > D2 GS 2003 > D3 S 2006 > D3 HSE 2009 > D4 HSE 2013 > D4 HSE 2015 > D5 HSE 2018 > DS HSE R-Dynamic P300e 2021
Question: Is the amber part of the lens a fresnel lens or is the fresnel lens built into the clear part?
Yes, I know. Fresnel was French I know it's not considered "kind" to say no these days, but no. Just no, ok? And if it's not ok, still no.
22nd Jun 2009 10:19 pm
Verydisco
Member Since: 02 Jan 2005
Location: A bit there, a bit over there and sometime at home, France
Posts: 1006
DG wrote:
Great stuff.
I have to ask... how secure and watertight are they when you have put them back together ??
I will tell you in 2 weeks when we are out in the country...
they should be as watertight as there is still plenty of the black goo on them (actualy none is gone, is it still on the two parts)
pressure is required to make sure the are as watertight as possible.
If they aren't as good, i will open them and ad some windscreen glue : that should do it for good. 8)
Note : the modification is reversible (as long as you don't lose the amber bit !) l=Oo\________/oO=l l:Ool======loO:l
Current
RANGE ROVER Vogue 4.4L TDV8 - 2012 - Orkney Grey, on Black, on Piano Black.
RANGE ROVER Vogue 4.4L V8 - 2002 - ex-2003 G4 Challenge Event Vehicle, Stage 3: Australia
FREELANDER 2 Td4 HSE "000" - Santorinin Black on Black
Gap Diagnostics' Classic and BT IID Tools!
Previous:
RANGE ROVER TDV8 x3
RANGE ROVER Td6 x1
RANGE ROVER Classic 3.5L V8 x1
DISCOVERY III x3
DISCOVERY II x3
DISCOVERY I x4
Last edited by Verydisco on 22nd Jun 2009 10:47 pm. Edited 1 time in total
22nd Jun 2009 10:23 pm
jjvd21
Member Since: 16 Jul 2007
Location: Chicago
Posts: 1070
Great write up!!!! A thin metal coat hanger works great for pulling up the headlight tabs. The ends of the hanger bend to fit the tab tops and its easy to pull straight up!16 D4 Landmark
05 D3 HSE V8
THE original D4 spotter
22nd Jun 2009 10:46 pm
SN
Member Since: 03 Jan 2006
Location: Romiley
Posts: 13710
This.... I like
Combine it with one of these and you're nearly there...
Steve N | 21MY Defender | 08MY Discovery 3 (history) | 06MY Discovery 3 (ancient history)
23rd Jun 2009 10:57 pm
Verydisco
Member Since: 02 Jan 2005
Location: A bit there, a bit over there and sometime at home, France
Posts: 1006
SN wrote:
This.... I like
Combine it with one of these and you're nearly there...
Hi, not mu cup of tea, but some may do like it.
I have found a solution yesterday for the side reflector replacement (originaly built in the amber trim), US specs side lamp hole hiding and for the turn signal bulbs (Phillips silver vision 581 indicator lamps, thanks to DG and ND).
More on that later today...l=Oo\________/oO=l l:Ool======loO:l
Current
RANGE ROVER Vogue 4.4L TDV8 - 2012 - Orkney Grey, on Black, on Piano Black.
RANGE ROVER Vogue 4.4L V8 - 2002 - ex-2003 G4 Challenge Event Vehicle, Stage 3: Australia
FREELANDER 2 Td4 HSE "000" - Santorinin Black on Black
Gap Diagnostics' Classic and BT IID Tools!
Previous:
RANGE ROVER TDV8 x3
RANGE ROVER Td6 x1
RANGE ROVER Classic 3.5L V8 x1
DISCOVERY III x3
DISCOVERY II x3
DISCOVERY I x4
24th Jun 2009 6:09 am
Verydisco
Member Since: 02 Jan 2005
Location: A bit there, a bit over there and sometime at home, France
Posts: 1006
NoDo$h wrote:
Question: Is the amber part of the lens a fresnel lens or is the fresnel lens built into the clear part?
Yes, I know. Fresnel was French
The Fresnel lens is in the amber part, so in theory, one needs to ad one, though i have no clue where to get on from , especially asap?
do you know a specific car that has one so i can visit the local junkyard / part dealer ?
txl=Oo\________/oO=l l:Ool======loO:l
Current
RANGE ROVER Vogue 4.4L TDV8 - 2012 - Orkney Grey, on Black, on Piano Black.
RANGE ROVER Vogue 4.4L V8 - 2002 - ex-2003 G4 Challenge Event Vehicle, Stage 3: Australia
FREELANDER 2 Td4 HSE "000" - Santorinin Black on Black
Gap Diagnostics' Classic and BT IID Tools!
Previous:
RANGE ROVER TDV8 x3
RANGE ROVER Td6 x1
RANGE ROVER Classic 3.5L V8 x1
DISCOVERY III x3
DISCOVERY II x3
DISCOVERY I x4
Not immediately, but I'm sure one of the resourceful types on here will know of a suitable donor vehicle with a large, flat, clear indicator I know it's not considered "kind" to say no these days, but no. Just no, ok? And if it's not ok, still no.
24th Jun 2009 7:45 am
Shrinky
Member Since: 05 Jul 2007
Location: Cotswolds
Posts: 2515
Good work But it's OK to pull the lens apart and remove the reflector but not to put an LED bulb in because it could fail an MOT Global Warming.... I'm luvvin it
24th Jun 2009 9:39 am
Verydisco
Member Since: 02 Jan 2005
Location: A bit there, a bit over there and sometime at home, France
Posts: 1006
Shrinky wrote:
Good work But it's OK to pull the lens apart and remove the reflector but not to put an LED bulb in because it could fail an MOT
Hi
about LEDs, the Philips Silver Visions do not come in our P27/7W (aka 3157 (took me a while to find out the name switched it seems...) so i need to source another 3157 in silver.
they are pretty rare but one can find them online (I always try to buy locally before buying on line)
In my search i found 2 types : the actual 3157 buld then the LED version of it.
does anyone know if this 32 LEDs bulb would compensate the fact there is no fresnel lens anymore ? As much as i would prefer the regular bulb type, the fresnel missing is a bit worrying. Also, doesn't the Disco 3 has probleme with LEDs (not enough resistance ?)
Current
RANGE ROVER Vogue 4.4L TDV8 - 2012 - Orkney Grey, on Black, on Piano Black.
RANGE ROVER Vogue 4.4L V8 - 2002 - ex-2003 G4 Challenge Event Vehicle, Stage 3: Australia
FREELANDER 2 Td4 HSE "000" - Santorinin Black on Black
Gap Diagnostics' Classic and BT IID Tools!
Previous:
RANGE ROVER TDV8 x3
RANGE ROVER Td6 x1
RANGE ROVER Classic 3.5L V8 x1
DISCOVERY III x3
DISCOVERY II x3
DISCOVERY I x4
The LED cluster with lamps all around the edge will give a distinctive pattern on the reflector, much more noticable than "normal" LEDs that only face forward.
A more expensive option that will REALLY look cool might be these babies
Sylvania make a 3157 amber lamp with the silver coating - Silverstar range. I think Sylvania and Osram are the same company? Only seem to sell these in the USA though I know it's not considered "kind" to say no these days, but no. Just no, ok? And if it's not ok, still no.
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