Headlights Self-destruct!

[Roger duRand]

Hello, all--First post!

My 1997 silver Boxster (currently in the shop for more convertible top troubles, re-paint and clear bra for front bumper-cover, and another set of P-Zero Rossos) has what I suspect may be a known problem with the headlights: The inner glass lenses have cracked directly in front of the lamps, and an ugly yellow-brown substance has gradually appeared around the cracks. My dealer,Woodhouse Porsche of Omaha (good people), informs me that the only recourse is to replace the entire assemblies at a cost of US$700 each. I really love this car and keep it showroom fresh (with 68,000 miles on the clock!), as well as possible, so this defect makes me crazy. I don't find any TSBs on this issue. I think that this is a result of an original design flaw, and that Porsche should be responsible for rectifying the situation. I do always drive with low beams on in daytime for defense, and it does get hot here in summer, but this obviously should not occur. I have always replaced lamps at the dealer with (I assume) OEM. Of course I will bite the bullet if I have to, to bring the car back to perfect, but I wonder if any of you have solved this problem in a more satisfactory way. What is the proper avenue to contact the right guy at Porsche to work with me? As plan 'B': do any of you have a salvage pair in PERFECT condition--latest manufacture that still fits this car--amber or clear signal lenses--that you might take US$400 for? Thanks in advance for your input!

Roger duRand

[geoff]

Sounds like somebody stuck bulbs that were too hot (too high wattage) in the headlights.

There should be lots on eBay (I just looked) that are cheap, probably from people replacing the ambers with clear. Look for "Boxster halogen headlight"

[Tool Pants]

What Geoff said.

Pull out a headlight and check both bulbs and I bet they are not the stock 55 watt bulbs.

Just about everything inside the headlight is plastic, including the reflector. The high wattage bulbs some people like to put in burn/melt the plastic reflector.

[Sputter]

1

[Roger duRand]

Sounds like somebody stuck bulbs that were too hot (too high wattage) in the headlights.

There should be lots on eBay (I just looked) that are cheap, probably from people replacing the ambers with clear. Look for "Boxster halogen headlight"

Thanks Geoff-- I'll check it out

[rsfeller]

ebay and other google searches will turn up used units for a 1/3 the price. Plus if you pay attention you will see the dismantlers (one in Oklahoma for sure) where you can contact them for items not on auction.

[Tool Pants]

Guy on Rennlist is selling a pair of 996 clear halogens. http://forums.rennlist.com/rennforums/show...ad.php?t=431622