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NoviceFixer · 05-22-2022, 10:53 AM

I have a 2007 Newmar Kountry Star and the driver’s side headlight has become unsealed. The butyl is disintegrating. Can anyone tell me how to remove the lens so I can reseal?

bobphoenix · 05-22-2022, 11:25 AM

Newmar built their bodies around existing parts that were available at the time...
For your model, I think you could got to someplace like "Rock Auto" or Car parts dot com, and ask for a the headlight unit is from a 2002 Ford Taurus headlamp assembly to replace the entire unit. If it looks like this...:

NoviceFixer · 05-22-2022, 02:50 PM

Thanks, but I think I figured it out. I was trying to reseal the light, had to remove the whole thing since the lens is factory sealed to the housing.

redbaron73 · 05-22-2022, 02:53 PM

Quote:

Originally Posted by NoviceFixer

Thanks, but I think I figured it out. I was trying to reseal the light, had to remove the whole thing since the lens is factory sealed to the housing.

I bake it in the oven for 4-5 minutes at 250F to get the lens separated, and then heat it as often as required to clean the old out.

Bobby Dowdle · 05-22-2022, 03:42 PM

Great job getting it apart. I would seal it 2 times to make sure you don’t have any gaps. Usually you have to replace the assembly if they get moisture in them.

redbaron73 · 05-22-2022, 03:52 PM

Here is a few pictures I took when I was doing the headlight upgrade on my 2022 London Aire.

I removed the oem halogen reflectors and replaced with Morimoto LED projectors.

Bonus picture showing the before and after low and high beam.

When using the new sealant, it helps to warm it up for 60 seconds in the 250F oven. Stretch it thin and push it down deep into the pockets around the entire assembly.

Return to oven for about 4 minutes and then firmly press assembly together again around edges. Finally clamp it while it's still warm and leave clamped while it cools for about an hour.