Headlamp Adjuster – 1996-2000 Bmw 5 Series E39

3D printable headlamp adjuster for the 1996-2000 Bmw 5 Series E39: download the STL file and print an affordable replacement for a discontinued or expensive original part.

About this part

These headlamp adjusters are for the BMW pre-facelift E39 series (5-series from 1996 onwards). The originals are made of some material that gets super brittle with age, and pretty much self destruct. Thus making the headlamps aim far too low, and wobble when driving over the slightest dump.

BMWs own solution is to supply new lamps as complete units, price probably approaching $1000.

To fix, you need to take the headlamp units apart, which is actually quite easy. There are various instructions on the net, The two manual adjusters simply fully unscrew to release. The third adjuster, connected to a motor, is released by turning the exposed 5mm plastic nut 90 degrees (not all variants have this feature). One word of warning: Do not touch the reflectors, they are very easily destroyed by attempts of cleaning.

You need one of each of these per side. They will work for the early halogen units, but may need modification for "angel eyes", and I have no idea about Xenon. Note also that the shape is different from the originals. I believe these may be slightly better - the originals were limited by what you could do with casting.

For best strength you should ideally print them laying down, but then some support is needed.

They will print fine standing up, but then they will not be as strong. The diameter and shape of the top ball is quite critical to get a suitably tight fit. Use a really healthy shell thickness and good infill, for strength.

ABS and ASA are probably good choices for material. PLA is easy, but is not as heat resistant and may degrade over time, and be a bit too brittle. PETG may also work. Probably Nylon would be good too.

Compatible vehicles

• 1996-2000 Bmw 5 Series E39

Always compare with your original part before printing. Fitment can vary by trim level and production date.

Specifications

Print settings

Standard FDM printing settings:
- Layer height: 0.2mm
- Infill: 70%
- Supports: As needed

What you get

A digital 3D model (STL file) of this part, ready to print on your own 3D printer or at any local print shop or online printing service. This is a digital download: no physical part is shipped. Not sure it fits your car? Contact us with your vehicle details before you buy.

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Design credit: original design on Thingiverse, licensed CC BY-4.0.