Cracked tail light lens

[Chip]

I broke the lens on my ‘21 Connect passenger side tail lights. It’s still working fine, but I bet it’s going to collect moisture in there. Is the fix is to replace the entire tail light assembly? That must cost hundreds, so hoping to avoid replacement, but it looks like the whole assembly is one piece. Any advice?

[Don Ridley]

Tail lights for ANY vehicle are expensive. Even the self service junkyards charge a lot for tail lights. Must be an industry standard. Online junkyards want $230 plus shipping.

 

Aftermarket tail lights are crap. Something about the plastic and diffraction pattern always looks cheap.

 

I have not found a glue that adheres well to the plastic (polycarbonate?).

 

 

 

 

 

[mrtn]

Get some transparent "stained glass" vinyl such as https://www.orafol.com/en/americas/products/oracal-8300-transparent-cal#

 

Pick the color matching best your tail light (cracked section) and cover the area fully so it won't stick out. You can even use this to darken the tail lights a bit for cooler look but won't have issues with visibility like you would with tinting.

 

I recommend doing both sides for equal look.

[Chip]

All, Thanks for the info and advice.

 

I stopped by a body shop I liked and talked to them about the tail light. They get the TL assembly from Ford. My dealer has the assembly in stock for $340. So, I could go get one and have a one shot resolution, but instead plan to order a tail lamp without circuit for $65 and take a chance. User reviews indicate it fits the Connect but the light socket holes are small.
 

if any of you know I’m making a mistake, please let me know. I figure it’s worth at least getting the part and taking a look at it. Something bugs me about throwing away a mostly usable tail light assembly. If this works, I get to reuse the light fittings. Hurray! Another fine Chinese product.

 

Will report on how it goes.

[Chip]

My new tail light lens arrived today. Out of the box, it compares well to the original lens (first photo). I included three photos comparing the bulb fitting holes. I used a Dremel and utility knife to clean up the holes. The plastic molding of the holes on the replacement lens left a lot to be desired (third photo). I used calipers and eye-ball to try to make the holes in the replacement the same as the holes in the original. The bottom hole is recessed on the original and raised a bit on the replacement (fourth photo), which worried me, but seems to have worked out okay.

 

The lamp assembly is fastened with two screws and two pins. The pins fit into a plastic socket that is pressed onto a metal tab. When I went to install I noticed one of the sockets for the pin was missing. The socket was still attached to the pin of the original lamp assembly. The hardest part of this whole install was getting that socket (the thing in the last photo that looks like a tall hat) off the pin of the original assembly. Fortunately I found a tool to help--a tiny crowbar, about 5" long with a sharp, forked end that I could force under the socket to pop it off the pin. I added a drop of super glue under the "hat brim" when I pressed it back into its' tab. Hope that holds.

 

So, it took some fuhduperating, but I'm pleased to have a tail lens back in place for $65 vs the $340 the dealer wanted for a replacement assembly. The lights all work and it looks good. It may yet fail. I don't think the glue between the lens and the housing goes all the way around, which makes me think water will get in there. We'll see.

 

Anybody know what that gray Denko Nitto thing is? (second photo) There are two of them. No wires visibly run to them.

Edited August 3, 2022 by Chip

[Don Ridley]

Nicely documented. I think the grey Denko cap is a breather (probably for condensation control). 

 

You should buy a set of trim panel removal tools. Everything on these vans is held by clips as you have discovered.

[windguy]

@chip - nice job, thanks for sharing. Hope it works out good for you. I admire your perseverance.

BTW - I like that carpet you have on the cargo floor. Very classy. I went with stock Home Depot dark gray off the bulk roll.

 

I second Don's suggestion for getting those removal tools. On Don's recommendation to get them years ago, I have used them many times. Also for non-auto use when you need a strong plastic scraper that won't damage a surface, like porcelain.