Any fix for broken bolts on rear light cluster - Alfa Romeo Forum
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Join Date: Nov 2009
Location: United Kingdom
County: West Sussex
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Brera 2.4 JTDm

Cry Like A Baby Any fix for broken bolts on rear light cluster

The (left) rear light cluster on my Brera contained condensation. I thought the easiest fix was to remove the bulbs however it appears the only way to get to the inner bulbs is to remove 4 nuts bolting the cluster to the car. Is that right?
Unfortunately after I removed the nuts and pulled out the cluster, I saw that 3 out of 4 bolts had broken from the bulb housing.
Has anyone had a similar problem and managed a successful fix?
Chris217 is offline  
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Status: 159 2.4 20007 plate 19,500 DPF/EGR by Adie (AHM)
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1) buy one from a scrapper.
2) two part (resin + hardener) epoxy or two part metalset adhesive and reglue them. If there is enough meat around the bolt holes you could drill them out to a larger size and fill the holes with the two part glue and then push the bolts into that. Two part adhesives are VERY strong if you leave them to set properly.

I love metalset. It is very strong.

If you do try drilling out be careful. it is easy for the drill bit to really bite into the plastic, twist the light or drill around and cause more damage to the housing.
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That'll be the way the moisture got in between the lenses and the
outer shroud.

So if you go down the repair route make sure you thoroughly dry/
force out all the moisture before repairing and resealing all cracks and joints,
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I had the same problem after the body shop over-tightened the light cluster bolts after a bumper respray.

I just relocated the bolts and secured them with epoxy body filler.

Did this over five years ago and everything still fine.
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