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Old July 15th, 2009, 12:24 PM
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1997 Defender 90
Join Date: Jul 2009
Location: CC, CT, USA
Posts: 3
Need help replacing headlamp panels please.

I have a 1997 defender 90 and have to replace the thin plastic panels surrounding the headlamps. I've taken off the orange and yellow lamp and the bottom lamp (the larger one) has two screws keeping on the circular mount. I've tried to unscrew them but they have some sort of plastic collar on the inside which keeps them from unscrewing all the way. I can't fit anything in the whole to anchor the collar while I unscrew it. Anyone know what I'm talking about here and know what I can do to get these screws out? I've also run into the same problem with the screws holding the side mirrors on but I can't see what's stopping the screw from coming out. Thanks in advance,


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Old July 15th, 2009, 02:31 PM
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East Coast Rover Co.
Just Defenders, nothing else.
D-90 Source Vendor
Join Date: May 2006
Location: Rockland, ME, USA
Posts: 4,601
They are called "nutserts" and it is common that they will spin when the truck gets older and a little corrosion happens between the screw and the nutsert. When they spin you have to hold the back of them, or drill/ grind off the screw head. Then replace them.
They suck however so a better way is to file the hole out square and put a RTC3744 plastic nutsert in and use a screw. That way, with no nutsert, the screw can never get stuck again during future services.
Side marker lights have them too and they are famous for sticking and/or spinning.

On the side mirrors they have a black plastic bushing on the screw that keeps them from backing off. Once you have the mirror off you can tap out the screws and you'll see the bushing.

I do not check PMs. Call or email if you need something.

ECR is not a parts source. We are not in the mail order business.
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Old July 16th, 2009, 06:13 PM
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Andrew J. Hutton
1993 Defender 110 200TDI
Join Date: Oct 2007
Location: Ottawa, Ontario, Canada
Posts: 735
I am giving well-nuts with button hex drive stainless machine screws a try, good antivibration properties and no need to over-tighten to get a secure hold. Will report once I have things worked out (still waiting for a huge shipment to start re-assembly)
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