2nd Gen Non-Engine/Transmission clearance light install nightmare...

[zman]

Today I decided to install the clearance light kit that has been laying around my garage for four months. What a PITA!!



The biggest problem had to do with the cheap white plastic inserts that you put in the screw holes. I followed the directions exactly and no matter what I did, those damn things spun when I tried to turn the screws in. Has anyone else had this problem?



The instructions indicate that the holes for these inserts should be 1/4" and that the inserts should press in. They pressed in, but it didn't require much effort. The screws are MUCH bigger than the holes in the middle of the inserts, making it difficult to turn the screws in and thus the spinning of the inserts.



I ended up having to have my buddy hold the white inserts from below with a pair of pliers while I turned the screws in. I tried to unscrew one to see if they would come out, but NO WAY. I don't know what I'm gonna do if a bulb burns out!!!! I still can't believe that I'm gonna have to drop the headliner again to fix this mess - ugh.



Please let me know if you have any ideas on how to fix this or if you encountered the same problem. Thanks!



Steve

 

[baby.driver]

I was careful to use a size smaller drill bit than called for.

When installing the screws put steady down pressure on the screwdriver and the screw holds that pressure on the insert against the roof.

Sorry you had all that trouble, mine was a piece of cake.



Jay

 

[Phil Stuart]

Steve, I had the same problem when installing mine. The inserts seem to be cheap and they turned while tightening the screws.

I got them all tight by pulling up on the lens a bit while turning the screws but dread the next time I'll have to change a bulb:{



I am trying to figure out another way I can fasten the lenses down onto the roof to make removal easier, but the holes are already 1/4" and that's all I've got to work with. I wonder if the factory uses the same method to install them

There has to be another way!

Let's hear some ideas from the membership!



Phil

 

[bighammer]

JB Weld or Well Nuts

How about JB Weld either on a nut for a machine screw or just around the inserts?



Another possibility would be to use well nuts and machine screws. They are rubber plugs that have a nut in the bottom. As the screw pulls tight, the rubber plug expands and mushrooms making a good seal and strong anchor. Not as prone to spinning loose either. They come in pretty small sizes.



One of the guys at our Detroit area BOMBing party had the same problem. I ended up helping him out because it was obvious it was not a one man job.



I'm glad I went with the aftermarket cheapies

 

[Phil Stuart]

Re: JB Weld or Well Nuts

Another possibility would be to use well nuts and machine screws. They are rubber plugs that have a nut in the bottom. As the screw pulls tight, the rubber plug expands and mushrooms making a good seal and strong anchor. Not as prone to spinning loose either. They come in pretty small sizes.



Where to buy these little buggers? Hardware store?



Phil

 

[Ncostello]

What if you slightly oversize the hole with a drill bit (very small amount) and then epoxy the anchors in place before installing the screws. Some of that mixable epoxy that sets up in about 15 mins and holds 2 tons should work, plus seal it up. Wal-Mart sells it. Comes in a twin tube setup. Depress the plunger and equal amounts of hardener and glue come out. Just a thought. Of course, you may never get them out again either.

 

[zman]

Thanks for the replies, guys.



Bighammer - My buddy mentioned the same thing you did about the rubber dodads. He was gonna check on them. I'll let you all know what he finds.



Ncostello - Epoxy sounds like a good idea. I think it would hold those cheap inserts pretty well.



I'll probably wait till one of the bulbs burns out to do the fix.



Thanks again!



Steve

 

[moon]

lites

Whats the procedure to lower the headliner,screws,snaps or clips what holds it in place. 2001 quad 4x4 Cummins, has overhead console.

 

[Philip]

Go to this site.



http://www.eastwoodco.com/



Then type in "thread inserts" into the search engine.



This is what I use to repair or install anything in sheet metal. These work very good. They do not leak when installed right. You can get them in many different threads and sizes.

 

[TWhiteside]

To remove the center console, there is two little tabs in the area that holds the Garage Opener. After releasing the tabs the Console will drop down in the front and it can then be towards the back. It will then drop down.



The Visors and Visor Clip, A-Pillar Cover and Grab handle above the door need to be removed. The headliner will easily come down.

 

[rweis]

I know you can get well nuts at marine / boat shops. There is also a HUGE online marine store, don't remember the name though, use to be E & B Marine. The well nuts generally have a cylinder of rubber (thickness and diameter varies) with a brass nut molded into the rubber. Used them on boats often. Were not expensive as I recall.

 

[bighammer]

A lot of hardware stores have well nuts too.