Headlight Control Units for BMW E39

These headlight control units are designed for the pre-facelift BMW E39 series (5 Series from 1996). The originals are made of a material that becomes very fragile over time. As a result, the headlights are aimed too low and may sway when driving over bumps.

Instead of replacing the entire assembly, the system can be restored by disassembling the headlight assemblies. To do this:

• Completely unscrew the two hand adjusters.
• The third adjuster, connected to the motor, can be released by turning the exposed 5mm diameter plastic nut 90 degrees (not all variants have this feature).

Warning: Do not touch the reflectors, as they are very fragile.

One unit is needed for each side. They are suitable for early halogen bulbs but may need modification for angel eyes and are not suitable for xenon. Note that the shape differs from the originals. For added durability, it is advisable to print them lying down, though this will require support. They can be printed standing up, but strength may be compromised.

The diameter and shape of the top ball are critical for a tight fit. It is recommended to use shells of sufficient thickness and good filling. ABS and ASA are likely good material choices. PLA is easy to use but less heat resistant and can degrade over time. PETG may also work, and nylon is likely a viable option.