The glass lens has seperated from the base/reflector part on both of my low beam headlights. I took the headlight assembly off & have removed the crome/stainless casing. It just appears that the glass needs to be reattached with some sealant or epoxy but I am unsure if that will work or what to use. Has anyone had similar issues? A friend of mine told me that I would have to replace the headlight assembly, which is quite expensive. Any advice?

 

just get some good epoxy,

steel reinforced epoxy by permatex is one of my personal favorites, but any good quality epoxy should be fine.

you don't need to replace the entire assembly.

I fixed mine with epoxy and they're water tight and working perfectly.

 

I did just as I was told & picked up some good epoxy & have them back together now. I have my fingers crossed that moisiture won't get in there again & cause my headlight bulbs to blow. Thanks for the advice.

 

Well if that doesnt work I have all 4 headlights that are cleared bra'd to protect from rocks for $175 +shipping. I believe that still less than 1 new 1

 

You don't by any chance have any '98-'03 XJ8 headlights do you?

 

Do you still have a complete set for sale? What year are they off of? Thank you

 

I was surprised how easy this job was. I used Goof Off and cleaned every bit of old adhesive off both surfaces. Then I allowed them to completely dry.

After cleaning both the lens and the reflector with Windex, I test fitted the two pieces making sure that the tang for the reflector didn't interfere with a tight fit.

I originally notice that the old adhesive had some flexibilty, even after 16 years. I decided not to use a rigid epoxy, thinking that some expansion between the glass and plastic housing might be needed.

Placing the rear plastic housing face up on a work table, I filled the groove with 3M Weatherstripping and emblem adhesive (black #08008). Placed the lens on top and put a quart can of paint on top, in order to weigh in down.

I let is sit overnight and it is perfect.