Modified Headlight Adjustment Tool (M04 03 05)

Publication date: 2005-07-01
Reference number: M04 03 05

MODIFIED HEADLIGHT ADJUSTMENT TOOL

TECHNICAL SERVICE BULLETIN

Reference Number(s): SI M04 03 05, Date of Issue: July 2005

MINI:	All
GROUP:	Tools and Equipment

SUBJECT

Modified Headlight Adjustment Tool

MODEL

All

SITUATION

Distribution of the following tool was completed through the Automatic Tool Shipment Program. Additional tools may be purchased through your PDC. All prices on this bulletin are introductory prices and are only valid during the Automatic Tool Shipment.

From 8/04 production, all MINI's have modified headlight adjustment screws. The current tool (90 88 0 632 100 SI M04 01 02 will not operate on these vehicles. A modification kit was developed and sent to every MINI dealer under the Automatic Tool Shipment Program. There was no charge to dealers for this kit during the initial shipment.

Headlight Adjustment Tool Conversion Kit

PN 90 88 0 632 200

Beveled gear with WAF 8 shortened adapter
Adapter with WAF 6
Metal friction tab
Plastic adapter holder

Fig 1: Headlight Adjustment Tool Conversion Kit

Change Comparison

Stock beveled gear with the long mounting head.
Modified beveled gear with the short mounting head - up to 7/2004 production.
Adapter for all models from 8/2004 production.

Fig 2: Change Comparison

TOOL MODIFICATION (632 100)

Loosen screw connection (1) until the gears (3) no longer touch.
Remove beveled gear (2) from mount (3) in the direction of the arrows.

Fig 3: Removing Beveled Gear
Place the new beveled gear (1) into the mount. Use a small amount of lubricant between the beveled gear base and the mount to cut the friction.
Turn screw connection (3) in the direction of the arrow until it stops. You may need to turn the handle of the tool in order to make the gears mesh properly.

Fig 4: New Beveled Gear Installation
Snap adapter (1) into the bracket provided (2) to prevent it from being lost. The adapter must be secured close to the head of the tool to prevent it from damaging to the vehicles paint.

Fig 5: Adapter In Bracket Provided

ADAPTER USE

When adjusting the headlights on an 8/04 or newer vehicle, insert the WAF 6 adapter (1) into the beveled gear (2). Move retaining ring (3) in the direction of the arrow to lock the adapter in place. The metal tab (4) is used to hold the tool to the adjustment screw.

NOTE: The gear assembly was removed from the tool for clarity.

Fig 6: Inserting WAF 6 Adapter Into Beveled Gear

MODIFIED TOOL APPLICATION

Due to the small size of the adapter (1), it is recommended to first attach it to the adjusting screw for the headlight (2).
Push the metal tab (3) to hold the adapter on the screw.

Fig 7: Adapter On Adjusting Screw For Headlight
Attach special tool 632 100 to the adapter (1).
Lock retaining ring (2).

Fig 8: Attaching Special Tool To Adapter
After locking the tool to the headlight (1) and before closing the hood, make certain that the shaft (2) has sufficient clearance with the headlight. Do not kink the shaft of the adjustment tool.

Fig 9: Locking Tool To Headlight