Sort of long, so don't read if you haven't the time...Nothing earth shattering here.
Don't you love those "five minute jobs" that end up taking well over an hour?
While driving home with SWMBO from a pleasant lunch out I stepped on the brake pedal in our 2004 Lincoln and was blasted by an unpleasant beep and a message popping up above the odometer display reading "Lamp Out".
I thought to myself, "Great, if you're so damn clever, why aren't you smart enough to tell me which of the gadzillion bulbs in the stupid car burned out?"
I figured since the alarm sounded just when I hit the brakes, it was likely a brake lamp bulb, and confirmed that when we got home by having my life mate get behind the wheel and tap the brakes with me looking.
It was a beautiful sunny afternoon, so I said, "I'll be up in about five minutes hon, I've just got to stick in a new bulb."
After removing a couple of fasteners and peeling back the carpeting in the trunk, I got to where I could reach three nuts on the studs holding the left tailight assembly in place and grabbed an 11mm deep socket and handle so I could spin them them off and pull assembly off to reach the bulb sockets. The first two nuts came off fine, but the third one just turned, but didn't back out, and it of course had to be the most inaccessable one of the trio, sunk in a recess in the sheet metal.
a little fooling around with an end wrench showed that the stud on the lamp housing was staying fixed, but the nut just turned around it. Clearly the sod who'd put that part of the car together must have tightened that nut until it stripped the stud and now the nut was just rotating around the threadless area.
Another five minutes or so was wasted with a small pair of Vise Grips clamped on the nut, twisting it CCW while pulling as hard as I could outwards, trying to get it to pick up the threads on the 5/8" or so of stud extending beyond it. That didn't work.
I couldn't bring myself to use brute force and crowbar the lamp housing loose, 'cause with my luck it would shatter and I'd be looking at paying an outragous price for a new one to help keep Ford out of bankcrupcy.
My nut cracker couldn't reach into the recess that nut was in, and it probably wouldn't have worked well 'cause the nut was one of those with a washer staked onto it.
I though of using a "flame wrench" on the stud and nut, hoping that the stud would get hot enough melt through the back of the plastic tailight housing and I could figure out how to rig a substitute later, but figured the way things were going, that was just too hackish to attempt.
I finally resorted to using a carbide burr in my Dremel and picking away at the side of the nut nut until I'd removed enough of it to wiggle it off the stud and free the tailight housing. That nut was no work of art by the time I got it off:
Then, I found out that the failed bulb was one of those newer style "wedge base" kind, and my box full of auto bulbs were all bayonet types, necessitating an unplanned 15 minute round trip to the nearest parts shop to buy a couple of new bulbs. (I always buy two, 'cause with my luck if I buy one I'll fumble, drop it, and watch it break. Buying two guarantees I won't break one and is the proximate reason why I have that box full of brand new bayonet base bulbs which won't fit any future car I get.)
Nothing else went wrong, thank G-d. I put a 5/16" stack of washers under a new nut so it couldn't get down to the wiped out threads on the stud and, "Bob's your Uncle", the job was done.
So guys, did I miss any other ways which might have shortened the job without risking ruining the stud or the tailight housing?
Jeff