Bill Seward writes: I tried the fix as mentioned here in the tips section.
My HL was rattling like crazy, enough to make me want to drive the car! Anyway, this fix is a modification of the fix with the foam on the mounting tabs, click Read More... for the details.
Get a tube of "SHOE GOO", available anywhere, and lay a THIN bead all around the rim of the headlight. Figure 1/16" bead will do it fine. Give it a couple minutes to get a "skin" on it, and reinstall the headlight rim.
That's it!
The rattle stopped completely, and the thin bead of Shoe Goo isn't strong enough to adhere the rim so tight you can't easily remove it. I think that you might even be able to reuse the bead, if you're careful removing the rim.
If you get any squeezin's on the outside of the headlight, it just picks off with your fingers. The stuff will not stick to chrome.
You MAY be able to get the same result using silicone seal, or caulk. Just remember to use a THIN bead, and wipe the excess off.
Bill Seward
alaska1@adelphia.net