Pelican Technical Article: Headlamp Switch Replacement Wayne R. Dempsey
Time: 1 hrs
Tab: $35
Talent:
Tools:
Torx socket set, 24mm deep socket
Applicable Models:
986 Boxster (1997-04) 987 Boxster (2005-08)
Parts Required:
New headlamp switch
Hot Tip:
Replace mini bulbs inside switch housing as well
Performance Gain:
Ability to drive at night again
Complementary Modification:
Replace bulbs in gauges
This article is one in a series that have been released in conjunction with Wayne's new book, 101 Performance Projects for Your Porsche Boxster. The book contains 312 pages of full color projects detailing everything from performance mods to changing your brake pads. With more than 950+ full-color glossy photos accompanying extensive step-by-step procedures, this book is required reading in any Boxster owner's collection. The book is currently available and in stock now. See The Official Book Website for more details.
Check out some other sample projects from the book:
It's not uncommon to experience a failure of your headlamp switch. Years of repeated use and abuse have a tendency to take their toll on the switch. Some symptoms of a faulty switch include headlamps that won't turn on, or perhaps inoperable fog lamps, just to name a few. In addition, there's a few small light bulbs contained within the switch housing that can burn out.
Replacement is fairly easy, and only requires about an hour of your time. See the photos in this project for the breakdown of the replacement procedure. The only tricky part for some people may be the removal of the large nut that fastens the switch to the vent housing. If you have a 24mm deep socket, then you can simply place this socket on the nut and turn it by hand. If you don't have access to a deep socket this size, then you may have to resort to a pair of needle-nose pliers to remove the nut.
For the 2005 and later cars, the procedure is super-simple. Press in the rotary knob on the light switch (but not to the limit), and turn the switch to the right. Then pull the entire switch assembly out.
The part number for the replacement switch is 996-613-535-00 (thru 2004) or 997-613-535-01 (2005-) and it costs about $125 from the online catalog of PelicanParts.com.
Figure 1
Begin by removing the two screws on the leftmost side of the dash with a Torx driver. In the lower right is shown a brand new headlamp switch assembly.
Remove the headlamp knob by pressing on the release tab and then pulling off the knob (red arrow, upper left). With the knob removed, you can access the hidden torx screw inside the inner bezel (yellow arrow).
Pull off the side vent and headlamp switch together (lower right). Disconnect the large circular plug, and then the smaller four-wire harness as well (yellow arrow). To remove the switch, simply unscrew the large nut on the face of the bezel (24mm deep socket).
Comments: Help! This comment is about the picture at Figure 3. I pulled off the side vent and headlamp switch together but removing the switch must involve more than simply unscrewing the large nut on the face of the bezel. I removed the large nut and still can't remove the switch. The replacement switch has lugs on it. It appears that the old switch has lugs too. Can't figure out how to rotate the lugs to the slots so it will release.
Followup: This is a follow-up to my earlier request for help. I figured it out. The light switch circuit board connected to the harness has to be pushed out to rotate the switch so the lugs can be pulled out through the slots, releasing the switch. Thanks anyway.
July 17, 2011
Followup from the Pelican Staff: Cool, thanks for the clarification! - Wayne at Pelican Parts
Check out some other sample projects from the book:
