[AT] tractor hauler a pain to install headlights.

[James Peck]

Some years ago I read some issues of a then DaimlerChrysler employee newsletter. One article covered a group that real world verified that all maintenance operations could be performed on a new model. If the maintenance could not be performed, the group would have to design a specialized tool or get a tool manufacturer to design the tool and offer it for sale.

They did all this after the vehicle had been designed and production was imminent. I am guessing that moving heaven and earth would be easier than getting the product design changed.

Toyota which emphasizes production efficiency not product design may not do it any differently.

Cecil Bearden AT List member, Oklahoma farmer, and Professional Engineer (crbearden at copper.net); My "new"2011 Silverado 2500 HD LTZ is the nicest truck and vehicle I have ever owned.  It runs great and for 185000 miles it uses no oil and pulls anything I need a 3/4 ton for.  However, the lights are terrible. I ordered a new set of headlights online for $140 instead of trying to buff out the old ones.  I spent ab out an hour trying to install them yesterday then gave up and looked at Alldatadiy.com.   The factory estimate is 1.1 hours for installation and that is about 3 hours short of what it will take.   My truck has a cowcatcher on the front,  It has to come off, the lower plastic and the bumper have to come off to get to the grill that has to come off and then I can get the headlight out. This is the problem of designing with AutoCAD and those other computer drafting programs. The designer has no idea of the clearance in the finished product. 1/2inch would have probably allowed removal without all the other parts being removed.  The grill could be removed if there was another 1/2 inch between the grill and the bumper. I decided to just try to buff the old ones.  Whoever authorized this installation should have been neutered with a dull knife.