I've tried searching, but to no avail; however it is entirely likely my keywords are incorrect. So here it goes....

I recently replaced my old halogen headlights with LEDs. The fitment of the replacement units is correct (it is the first thing I checked). However, now when I turn off the headlights there is what sounds like a "clunk" when they close. Through a process of elimination I redid my steps for reassembly, and found out when I skip the step to reinstall the upper bezels the lights close with nary a sound. I tried reinstalling the upper bezels, and the clunk is back. I even tried reinstalling the upper bezels without the lower ones installed, and got the same "clunk" sound; yet when I install the lower bezels without the top bezels, there is no "clunk" sound. That's as far as I have been able to narrow it down.
This car is a mint condition convertible, 1990, with 67K when I got it (71K now) back in April 2020. There has been no molestation, etc.: besides the new head unit and speakers as well as the aforementioned headlights, it is 100% bone stock.
And, I don't know if the lights were making this clunking sound before I replaced the headlight units. I just know that it is now.

I'm assuming there is a fix for this, but damned if I know what it might be.
Anyone ever come across this before?

R/
Steve

 

I'd start by disconnecting your battery, leaving the headlights up beforehand, and then turning the manual actuation **** for the motors on both headlights incrementally while watching/feeling for any resistance, taking note to put them back to their original position afterwards. What brand led lights did you get? It could just possibly be poor manufacturing/fitment.

 

If the lights were poorly fitting, then why only make this noise when the upper bezel is installed? As far as I can see, the lights are snug and good. I put in place the upper bezel and look around for what might be snagging it, but I cannot. On a side note, the drivers side is much more noticeable (loud) than the passengers.
And I am not discounting your suggestion (in fact I appreciate it), SwappedNA, just trying to whittle this down to try and avoid having to break loose anything else.

 

they look like they are in correctly. is the upper bezel hitting anything on the way down? are the new lights really heavy?

there is a bump stop in there at the bottom, and it is adjustable, but maybe it is best to disconnect the battery (or pull the retractor fuse) and manually run the light through its range of motion and see if there is anything obvious

(BTW that is minty clean!)

 

I think I have solved my problem. I used two "suitable sub" screws for the bezels which turned out not to be so suitable, after all. Without those two screws in either of the bezels, they are smooth and buttery. So I just ordered 12 of these, never hurts to have extras: https://www.atkinsrotary.com/store/8...01-51-611.html
I will install them in a couple days. If they do NOT do the trick, I will update and go from there. If they do, thanks everyone for your input.
And thanks j9fd3s, I hope I can keep her as clean and stock as possible (even down to the screws!).

 

the one i'm working on right now came in pieces, so that are is clean on that car because i had to clean it, and paint it, and find the bolts, and put it all together and do the adjustments! it was a lot of work!

 

I believe you.