Headlamp adjusters for BMW E39 vehicles

thingiverse

These headlamp adjusters are specifically designed for the BMW E39 series (5-series from 1996 onwards). The originals are constructed from a material that becomes incredibly fragile with age, causing them to self-destruct over time. This leads to the headlamps aiming significantly lower than they should and wobbling excessively when driving over even minor bumps. BMW's solution to this problem is to replace the entire lamp unit as a complete assembly, which likely costs around $1000. To make repairs, you need to disassemble the headlamp units, a process that is surprisingly straightforward. The two manual adjusters can be completely unscrewed to release them. However, the third adjuster, connected to a motor, requires turning the exposed 5mm plastic nut by 90 degrees (not all variants feature this option). It's crucial to note: do not touch the reflectors as they are extremely vulnerable to damage from cleaning attempts. You will need one of each of these adjusters per side. They should work for early halogen units, but may require modification for "angel eyes," and I have no idea about Xenon compatibility. Additionally, be aware that the shape differs significantly from the originals. I believe these new adjusters might offer a slight improvement over the originals due to their design flexibility. The originals were limited by what could be achieved through casting. For optimal strength, it's ideal to print them in a horizontal orientation, but some support material will be required. Alternatively, they can be printed standing up, although this may compromise their strength. It's essential to ensure that the diameter and shape of the top ball are precisely correct for a snug fit. To maximize durability, use a generous shell thickness and a high-quality infill setting. ABS is likely a suitable material choice due to its balance of properties. PLA might be somewhat too brittle, potentially degrading over time, while PETG could also work. Nylon would probably be an excellent option as well.