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Headlamp Sensor Linkage Rod Broken

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Old 10-14-2009, 11:33 AM
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Headlamp Sensor Linkage Rod Broken

I have just purchased (used) my first RX-8 - what an awesome car !

I'll cut to the chase before I bore too many people with my tale;
Does anyone have a used front headlamp auto-leveling sensor assembly that they no longer need ? (Maybe you've replaced a defective unit with a new one, and have no use for the defective one).
I do not need the "electrical box" - it's the cast linkage rod (the grey rod) that I'm really after. The black brackets that this rod connects to would also be useful. I would be willing to pay postage and compensate you for your time.

Here's my story. I hadn't noticed the headlamp warning light when I test drove the vehicle. Or if I did, I probably just though that it was indicating driving lights on or something. Anyway, having purchased the vehicle, on my first drive to work, it was kind of obvious that something was amiss. Driving in the dark of the early morning around some twisty, unlit country lanes, I had a very bright view of the road about 10 foot in front of the car - and everything else was in darkness. I asked the gods of deer and other fender bending creatures to protect me, and made it into work okay.
Reading the posts on RX-8.com, it seemed obvious that my problem was a faulty sensor. However, it turns out that the problem wasn't the usual corrosion in the sensor. The first thing that I noticed was that the cast rod that transfers the motion from the suspension to the sensor was broken. Then it became clear that the lower bracket that mounts this rod to the suspension arm was severely twisted. I'm still having trouble deciding how this might have happened. My best guess is that someone put an axle stand under this area and it bent the lower bracket. This moved the connecting rod outboard. Then when the vehicle was next used, the connecting rod snapped when it struck the anti-roll bar due to its new position. I've attached some photos for "show and tell".
I needed a quick fix. The connecting rod is made of a cheap cast material and I didn't think I could reliably repair it. I did an electrical check of the sensor, and it worked fine. So my interim solution was to attach the aluminum bracket shown in the attached photos onto the sensor arm. The purpose of this is to hold the sensor in a fixed position (as close as I could get to a central location - measuring electrical resistance between the sensor connector pins, rather than measuring angles).
This fix seems to have done the job. The warning light is off, and the headlamps seem to be aiming in the right direction. However, I would really like to get a replacement connector rod and brackets, just so that I can get the system working normally again.
So - does anyone have a connecting rod that they could spare ?
Thanks for listening,
TT

Headlamp Sensor Linkage Rod Broken-busted-front-sensor-brkt.jpg

Headlamp Sensor Linkage Rod Broken-busted-front-sensor.jpg

Headlamp Sensor Linkage Rod Broken-front-sensor-temporary-fix.jpg
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