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How To: Perform a Heavy Duty Headlight Restoration
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By Counterman
Sealed-beam headlights were simple and easy. For years, that’s all there was. A headlight was held into its bucket by a round or rectangular stainless-steel trim piece, with either three or four screws. Sometimes you had to remove a decorative trim piece first, but still always just a few screws.
Then it got even easier throughout the 1980s as the industry transitioned from the traditional sealed beam to composite headlights with replaceable halogen bulbs. There wasn’t anything wrong with the sealed-beam design; they worked great. But there were only a few options, which limited automotive design.
With composite headlights, automakers were designing cars with the look and aerodynamics that were previously restricted by one simple part. The best thing was, you simply opened the hood, and you could see the rear of the headlamps with the connector for the bulb protruding out the back. You unplugged the bulb, removed a retaining ring and out it came. It was that easy, and many still are that way. There’s not much to it.
Sticker Shock
However, all good things come to an end, and we’re seeing more and more cars where the aerodynamics, the shape of the front end and the tight, space-restricted engine compartments make it impossible to get to (or in many cases even see) the rear of the headlamp.
Often, you must completely remove the headlamp to access the bulb. Sometimes you have to remove fender liners, or in worst-case scenarios, even the bumper cover or grille. There are times when it may take 45 minutes or longer to replace a headlight bulb. It’s uncommon – but it happens, nonetheless.
Replacing headlight bulbs typically has been so simple for so long that most consumers have been programmed to think it’s a quick and easy job. You could literally replace one in less than a minute, and many shops – especially for regular customers – got in the habit of replacing them for only the cost of the bulb.
That’s become a thing of the past as they get harder and harder to get to. Imagine the consumer’s shock to tell them it’s going to be $50 to $70 in labor just to replace a headlight bulb. That’s when a lot of people decide they can do it themselves. How hard can it be after all? Either way, getting access to the bulb is Step 1. You’re home free after that, but there are a few particulars to pay attention to, which hold true for any headlight-bulb replacement.
Don’t Touch the Bulb
First and foremost: Don’t touch the bulb. Many people ask why. The natural oils on your skin will transfer to the surface of the bulb. As the bulb heats up, it expands. If there’s oil on it, that spot will get much hotter than the rest, expand at a different rate and cause it to crack or shatter.
The best advice is to leave the bulb in its packaging until after you’ve removed the original and are ready to reinstall the new one. Then carefully remove it, holding it by the electrical connector. Compare it to make sure it’s the same, then install it in the housing. If it does get oil on it or you accidentally touch it, you can simply wipe it down with rubbing alcohol and a clean rag.
Inspect the Wiring Connector
When the bulb is disconnected, it’s important to look closely at the wiring connector. It’s very common for them to be melted and burned. This often is the root cause of the headlight light not working as opposed to a bad bulb. It happens because headlight bulbs get very hot, and they go through continuous heat and cooling cycles. This constant expansion and contraction eventually weakens the tension on the electrical terminals, creating high resistance.
With resistance comes additional heat, and some aftermarket bulbs may draw a higher amperage than OE bulbs, compounding the problem. Since this problem is so common, most of the common wiring-harness connectors are readily available as a pigtail (connector with wires installed), and just have to be spliced onto the original harness. Some of them feature design improvements to handle higher heat and a higher current too.
If you’re replacing a sealed-beam headlight, it’s still a good idea to closely inspect the wiring connector. These often look OK, but don’t provide a good connection. They frequently go bad too due to corrosion and age, primarily because they aren’t sealed. These connectors are still available, as well as a pigtail harness.
The adjusters on sealed-beam headlights also break a lot simply due to age, but these are generally available too, so they’re a good upsell, and usually an easy one. Most cars with sealed-beam lights are classics, which people are willing to invest time and money in. With composite lights, this is the perfect time to sell a headlight polishing kit to bring clarity back to old lenses. So, changing headlight bulbs? It’s usually easy, but it can be hard, and there’s always an opportunity to help your customer make the most of the job.
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By Counterman
Momentum USA Inc. is introducing a new brake-pad offering as an extension of AmeriPLATINUM, Max Duty.
The brake pads will be the most complete pads offered by AmeriBRAKES, providing three levels of protection for fleet, emergency-service and other severe-duty requirements, according to the company.
The 100% copper-free brake pads feature A.R.M. – R.A.C. technology. A.R.M. refers to the mechanical-attachment method of securing the brake pad to the backing plate. Rust Abatement Coating (R.A.C.) helps prevent possible pad delamination and premature wear using zinc-coated galvanized technology.
The A.R.M. – R.A.C. technology helps with NVH issues and helps to ensure a quiet brake system, according to Momentum USA.
“By mitigating ‘rust-jacking,’ these pads will have the benefit of longer life,” the company said in a news release. “100% manufactured and distributed in North America, Max Duty pads deliver dependability, exceed expectations and provide peace of mind in the most severe conditions.”
AmeriPLATINUM Plus Max Duty brake pads will be available for distribution and sale in the coming weeks.
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By Counterman
The University of Aftermarket, through Northwood University, is accepting registration for this year’s Heavy-Duty Leadership 2.0 series.
“Heavy-Duty Executive Development Series is a cornerstone in the industry’s efforts to foster the development of a new generation of visionary executives who will help drive the heavy-duty aftermarket to new heights of excellence in leadership and performance,” said Thomas Litzinger, executive director of the University of the Aftermarket, and associate professor for Northwood University.
Heavy-Duty Leadership Development Series is an intense and intellectually challenging four-day residential leadership development program designed for heavy-duty professionals in all segments of the heavy-duty market.
“Our program will be led by top heavy-duty industry leaders and coveted thought leaders who collaborate with faculty from Northwood University’s DeVos Graduate School of Management and the University of the Aftermarket,” Litzinger added. “This unique partnership allows for an intensive course that is focused on advancing leaders who purposely perform at achieving key organizational outcomes for all levels throughout the heavy-duty aftermarket.”
The Heavy-Duty Leadership experience includes a blend of industry research and market analysis; discussion and debate of new challenges and competitive strategies; individual skills training in team management, leadership roles, strategic thinking and planning; insight into supply chain solutions and industry trends; as well as engaging presentations by industry leaders.
Students who complete this course will be able to:
Explain the heavy-duty market and how it is integrated into the global aftermarket. Distinguish and communicate strategic industry trends and outcomes across the heavy-duty industry and identify and name the significant contributors and stakeholders in the industry. Identify and demonstrate advanced leadership techniques related to a rapidly evolving, post-pandemic global economy. Analyze the challenges and opportunities facing service dealers and describe essential sales leadership techniques focused on differentiating their relationship development skills compared to the competition. The keynote speaker will be Don Reimondo, former president and CEO of HDA Truck Pride. Other speakers include Tina Hubbard, president and CEO of HDA Truck Pride; Mike Harris, president, sales and operations of Fleet Pride Heavy-Duty Parts and Service; John Passante, president and CEO Organizational Development Group; Clint Longenecker, University of Toledo; and Rick Guirlinger, president, Bourke Services LLC.
The series will be held July 16-20 at Delta Hotels by Marriott in Farmington Hills, Michigan.
The cost is $3,450 per attendee, which includes tuition, materials, snacks and lunch. Students who complete the course will earn 3.5 continuing education units (CEUs) toward their automotive professional designation.
To learn more, visit
link hidden, please login to view. The deadline to register is June 30. Contact Litzinger at [email protected].
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By Counterman
The U.S. Department of Transportation’s National Highway Traffic Safety Administration (NHTSA) announced a notice of proposed rulemaking that would require automatic emergency braking (AEB) and pedestrian AEB systems on passenger cars and light trucks.
The proposed rule is expected to dramatically reduce crashes associated with pedestrians and rear-end crashes, according to the agency.
NHTSA projects that the proposed rule, if finalized, would save at least 360 lives a year and reduce injuries by at least 24,000 annually.
In addition, the AEB systems would result in significant reductions in property damage caused by rear-end crashes, according to NHTSA. Many crashes would be avoided altogether, while others would be less destructive.
“Today, we take an important step forward to save lives and make our roadways safer for all Americans,” U.S. Transportation Secretary Pete Buttigieg said on May 31. “Just as lifesaving innovations from previous generations like seatbelts and air bags have helped improve safety, requiring automatic emergency braking on cars and trucks would keep all of us safer on our roads.”
The
link hidden, please login to view is a key component of the department’s National Roadway Safety Strategy (NRSS), which was launched in January 2022 to address the national crisis in traffic fatalities and serious injuries. The NRSS adopts the safe-system approach and builds multiple layers of protection with safer roads, safer people, safer vehicles, safer speeds and better post-crash care, according to the agency. As part of the safe system approach, the proposed rule highlights safer vehicles and the DOT’s effort to expand vehicle systems and features that help to prevent crashes. An AEB system uses various sensor technologies and sub-systems that work together to detect when the vehicle is close to crashing, and then automatically applies the vehicle brakes if the driver has not done so, or applies more braking force to supplement the driver’s braking as necessary to avoid or mitigate the severity of the crash.
“We’ve seen the benefits of the AEB system in some passenger vehicles already even at lower speeds, and we want to expand the use of the technology to save even more lives,” NHTSA Chief Counsel Ann Carlson said. “That’s why our proposed rule would require all cars to be able to stop and avoid contact with a vehicle in front of them up to 62 miles per hour. And the proposal would require pedestrian AEB, including requiring that AEB recognize and avoid pedestrians at night,” “This proposed rule is a major safety advancement.”
If adopted as proposed, nearly all U.S. light vehicles (gross vehicle weight rating of 10,000 pounds or less) would be required to have AEB technology three years after the publication of a final rule.
This notice is a direct response to a provision in the
link hidden, please login to view to create a rule to establish minimum performance standards requiring that all passenger vehicles manufactured for sale in the United States be equipped with an AEB system. A preliminary regulatory impact analysis that presents the benefits and costs associated with the proposed rule also link hidden, please login to view. The post
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