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I have a 1999 996 Cabriolet with Halogen headlights. I live in Phoenix, AZ and noticed when waxing the car the rubber seal around the headlight that mates to the fender well is degraded and rubbing off (smearing).

I contacted Porsche trying to obtain new rubber seal and they state it is part of the Headlight assembly and need to order entire assembly, P/N 996.631.163.20 (LHS) & 996.131.164.20 (RHS) which is expensive. I have contacted many Porsche online part sites and they advise the same. I sent email to Bosch hoping they might replace seal, waiting for a response. I have been told this seal is secured within plastic housing snapped on to headlight assembly, therefore should be replaceable.

Any suggestions to find the rubber seal at nominal price?

P.S. I went to Porsche dealer, they took new light out of box and where able to physically find a P/N on rubber seal which is 996.631.172.00. This P/N could not be looked up on the computer. They sent email to Porsche to determine if can order rubber seal. Will advise when I hear.

Thanks,

Bob

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Hi,

Any update on this issue? I too am in need of the rubber seals..

Thanks

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I don't see a part number for the just the seal in the parts list - perhaps you can send an email call Sunset Imports (Porsche Parts at Dealer Cost) and thye might be able to find it.

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Talked to Luke from Sunset Porsche... No part number for that rubber seal. You have to purchase the whole headlight assembly and it will come with the seal :o ...

Anyone have any idea on a fix on this?

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Does anybody had success in obtaining this headlight rubbers?....Just bought a 996 here in Saudi...but my rubbers are totally disintegrated..

I saw that the headlight units are from Hella, did anybody try to contact them already?

Chris

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I replaced the rubber seals on my headlights with the referenced steel product. It is definitely a generic product and does not fit like the factory seal. The edges on the original factory seal are rounded and it is formed to fit the curvature of the lights. The new rubber seal width also had to be trimmed a bit in places to allow the headlight to fit back into the body without excessive force. On a close inspection this retrofit does not look as good as the original, however it is far superior to the original once the original seal has degraded (mine was turning to goo). This product can also be easily removed should a better solution be found. There is probably a generic product out there that would be a better replacement but I didn't want to go through the trouble to discover it given that someone had already found a serviceable solution. Best of luck on your project!

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The rubber is so goo-like that I use it's viscosity to mold or stretch it with my fingers and push it back to where it is supposed to go. Probably not what Dr Ferdinand would do, but it works.

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Same type of goo on mine.  I was thinking of trying out some various sizes of screen spline (the rubber cord that holds a screen in a frame), but I haven't tried that yet.  Maybe I will now.

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996 Headlight Gasket repair ?  I have been searching for a fix for 3 years... and I think I have found a good replacement. See Photos below.

This hollow "P" shaped 1/4 inch tubing ( 1/2 inch overall width ) with a tape backing worked great on my 2000 C4. Ordered from McMASTER-CARR   https://www.mcmaster.com/ - "High Temp Rubber Seal" - Pt # 1129A992 "Style B".

https://www.mcmaster.com/#1129a992/=1e35sf5

A 5-foot section does one headlight with some left over. Two 5-foot rolls cost $19 plus shipping & tax. See the part number details in photo.

 

A few notes on installation. Clean all the old rubber "Goo" from the area with alcohol including the channel between the clear lens and the black headlight case. This new tubing flange will fit inside this channel. Insert it with the tape side facing away from the lens and as you work it around the lens remove the tape backing. It will stick to the channel and stay put without any other clamping. Run the tubing out about an inch beyond the lens and when you reinstall the Light assembly, tuck the extra tubing under the light between the fender.

 

Because this is hollow tubing it compresses very well as the light is installed in the fender. And if it bulges out any it is easily pushed back in place with a finger or a small plastic tool. It is Black but a bit shinier that the original which I could compare to my other lamp which is new having been replaced after damage.  Good luck returning your 996 to like new... :-)

 

 1204420551_IMG_20180809_120907996HdlampFix2.jpg.112098f6a12c1e81b9c5362108cac363.jpg2125410497_IMG_20180809_120900996HeadlamptrimSml3.jpg.d61ecd19a7afe7cca3c432d842f4d587.jpg1350134618_IMG_20180809_140258996HdlampFixRubbersml.jpg.e512d39eaa12f602d99195d224591462.jpg871344550_IMG_20180809_120917996HdlanpFix1.jpg.7e7be0be8c31256987fb9cc4a8083e90.jpg

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Thanks for all the information. I am new to Porsche and new to the forum. Just acquired a '03 Boxster S. It is a well taken care of car mechanically, but the AZ sun has done some pretty horrible things to the car. Slowly getting all the ticky tack things fixed.

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On 8/9/2018 at 8:56 PM, jacks996 said:

996 Headlight Gasket repair ?  I have been searching for a fix for 3 years... and I think I have found a good replacement. See Photos below.

This hollow "P" shaped 1/4 inch tubing ( 1/2 inch overall width ) with a tape backing worked great on my 2000 C4. Ordered from McMASTER-CARR   https://www.mcmaster.com/ - "High Temp Rubber Seal" - Pt # 1129A992 "Style B".

https://www.mcmaster.com/#1129a992/=1e35sf5

A 5-foot section does one headlight with some left over. Two 5-foot rolls cost $19 plus shipping & tax. See the part number details in photo.

 

A few notes on installation. Clean all the old rubber "Goo" from the area with alcohol including the channel between the clear lens and the black headlight case. This new tubing flange will fit inside this channel. Insert it with the tape side facing away from the lens and as you work it around the lens remove the tape backing. It will stick to the channel and stay put without any other clamping. Run the tubing out about an inch beyond the lens and when you reinstall the Light assembly, tuck the extra tubing under the light between the fender.

 

Because this is hollow tubing it compresses very well as the light is installed in the fender. And if it bulges out any it is easily pushed back in place with a finger or a small plastic tool. It is Black but a bit shinier that the original which I could compare to my other lamp which is new having been replaced after damage.  Good luck returning your 996 to like new... 🙂

 

 1204420551_IMG_20180809_120907996HdlampFix2.jpg.112098f6a12c1e81b9c5362108cac363.jpg2125410497_IMG_20180809_120900996HeadlamptrimSml3.jpg.d61ecd19a7afe7cca3c432d842f4d587.jpg1350134618_IMG_20180809_140258996HdlampFixRubbersml.jpg.e512d39eaa12f602d99195d224591462.jpg871344550_IMG_20180809_120917996HdlanpFix1.jpg.7e7be0be8c31256987fb9cc4a8083e90.jpg

Thanks for the information. I got the silicone seal and looks great and will last much longer than the original rubber.  I also used some auto rubber sealing https://www.amazon.com/gp/product/B07K43BT61/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1 around the lense where the original rubber was. 

 

Edited by Angel Martin
Additional info

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