I think im going to play it safe and remove them, I have to go buy a taper proof torx 25 screw driver.

 

You will be fine baking everything like Jerry said (I dont know anyone who actually removes the ballast).

I figure you could screw something up worse by taking out the projector lens and ballast.

 

Okay, but should I take out the light bulbs and xenon bulbs?

 

Try it. It's a pain in the ass. You probably run a greater risk of messing the bulbs up since they're ultra-sensitive to debris/oil.

 

Bingo. Even a simple finger print on the xenon bulb becomes a 'hot spot' and may cause permanent discoloration or even structural failure. I wouldn't worry about the headlight or ballast if you keep the temperatures around 200F. Its probably a safe bet that these components normally operate at a higher temperature than they will experience in the oven.

So yeah, take out the light bulbs, but leave the ballast and projectors intact.

 

Alrighty, I'm gonna start baking then. Thanx

 

Don't fock it up.

 

Well I got them apart fine, but reassembly is a PITA. I finished one but it wasn't able to put it together as tightly as it was. I baked it like three times on reassembly trying to get it tight enough but it hardly seems to budge. Do u think its okay if its not as tight as it was? All the clips are locked, but the gap seems to be a little bit larger then it was originally.

 

If all the clips are locked, everything is snapped back together, and you used a generous amount of silicone sealant, you should be fine.

I personally had a harder time getting them apart, and putting them back together was easier. There was so much sealant in my lights already, I didn't have to use alot of my own sealant. I put some extra sealant in, and re-baked the lights to melt the sealant.

 

I put both of them back together and put a bunch of extra sealant in the gap. Hopefully that will take care of any possible leaks. Just gotta paint the bulbs and put them back on the car tommarrow.