I've probably found a way to solve the “sticky headlight†issue.
I'll describe my system while it is fully made from behind
First of all remove the headlight by lifting the sleds and pulling the power cord. Step already described.
Move on a table on which was placed a cloth to avoid scuffing the front screen.
Access to the lamp housing by removing the rear cover. Remove bulb power cord. Remove the bulb being careful to store it safely where it can’t be broken.
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Remove the cover of the ballast. Remove the ballast that can be left dangling.
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Unplug the power cord of the actuator (solenoid) of the eyelid.
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Loosen and remove the two screws holding the reflector.
Remove the reflector through the ballast hole; the first part of the reflector to come out is the part where the bulb is fixed (sorry but I don’t know how to say).
sorry no pics
Loosen and remove the 3 screws holding the lens so you’ll be able to undo the two screws holding the solenoid.
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Remove the solenoid having dropped the L-shaped spring that transmits the motion from the coil core (how do you call it) to the eyelid. Remove the coil core.
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Then I used a 1200 sandpaper to clean (recalibrate) the coil core. I did it by using the drill and by hand.
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Click image to enlarge
Then I cleaned both parts, solenoid and the core, with solvent and a cotton bud.
Reassemble everything in reverse: 1 - solenoid with eyelid spring, 2 – lens structure, 3 - reflector, 4 - ballast and finally 5 - the bulb.
Actually everything works fine while before it sticked at the first operation. Will let you know in the long run.
Apologize for my english. Feel free to correct me.
Filippo
3rd Jan 2012 4:24 pm
Martin Site Admin and Owner
Member Since: 06 Nov 2004
Location: Hook Norton
Posts: 18459
Excellent write up as always 06 D3 SE / 15 LR D90 XS SW / 88 LR 90 Td5 / 68 BMW 2000 ti
Any issues with the site let me know!
30 minutes and not too tricky, really
easy to put back together as well
a magnetic screwdriver would be useful to catch little screws
F.
3rd Jan 2012 8:28 pm
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1787
Great write up filo I've been looking for a solution to this for months hopefully its a permanent fix - keep us posted!
3rd Jan 2012 11:24 pm
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1787
mines is adaptive, just can't see how to access the solenoid
4th Jan 2012 2:23 pm
sarumlight
Member Since: 07 Nov 2008
Location: Off the Plain
Posts: 1590
Great write-up Filippo!
So was the core noticeably corroded before, and moved more freely once you'd sanded it? I wonder if something like Ferrosol would help protect the surface without gumming it up?
4th Jan 2012 4:32 pm
zig
Member Since: 09 Sep 2005
Location: Scotland
Posts: 619
For non adaptive xenons what is the effect of sticky headlights on the beam pattern when dipped or on full beam (or is there some other effect)?
5th Jan 2012 1:08 am
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1787
Adaptive or non-adaptive, the effect is the same, inevitably they stick on the Hi-beam position and oncoming drivers suffer retina burn!
5th Jan 2012 11:53 am
zig
Member Since: 09 Sep 2005
Location: Scotland
Posts: 619
apologize for the delay
forgot to say mine are the non adaptive and so i don't know if there's something different in disassembling the adaptive
the core was not corroded IMO it's simply too tight in his housing, i mean there was not enough play
i'd avoid lubricating the core and the reason is it becomes hot when used for long times
F.
5th Jan 2012 4:43 pm
J@mes
Member Since: 10 Nov 2008
Location: Bomber County
Posts: 4547
Just done this, it's a little bit fiddly but has solved the shutter issue on one of my headlamps. The other is still sticking, despite being apart 5 or so times to have the solenoid core "modified" as well as checking everything else is free.
The solenoid works, but for some reason it still sticks when I try to shut off the main beam, and smacking the front of the light seems to be the only way to free it off, or poking the arm with a screwdriver when it's sticking.
Not sure where to go from here really, possibly new headlamp 2014 D4 XS
2005 D3 SE - Gone
29th Feb 2012 5:43 pm
Biffysun
Member Since: 09 Jul 2011
Location: Central
Posts: 1787
James they don't sell the solenoid as a seperate part but why not post up for a second hand/damaged Xenon, adaptive/non-adaptive/NAS anything and strip it for the solenoid? If its adaptive theres a lot more dismantling to get it out but it worked for me
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blimey looks hard.
hopefully its a permanent fix - keep us posted! 
mines is adaptive, just can't see how to access the solenoid 
