Head light assembly and method for assembling

A headlamp assembly comprising:

• an LED module comprising a base and opposing side walls projecting vertically from opposing sides of the base, each opposing side wall having a spring-receiving opening formed therein;
• a spring disposed at least partially between the opposing side walls of the LED module with end portions of the spring projecting in opposite directions from the side walls of the LED module;
• and
• a reflector carrier comprising a platform including a front edge portion and opposing brackets extending from opposing sides of the platform, each opposing bracket having a spring-engaging slot formed therein,
• wherein the LED module is disposed at least partially between the opposing brackets of the reflector carrier with the end portions of the spring extending through the spring-engaging slots in the opposing brackets whereby forces applied by the spring in the Y- and Z-direction mechanically couple the LED module to the reflector carrier.

A method of assembling a headlamp comprising:

• inserting a spring into spring-receiving openings in side walls projecting vertically from opposing sides of a base of an LED module so that opposing end portions of the spring project in opposite directions from the side walls;
• engaging the opposing spring end portions with spring-engaging slots formed in brackets extending from opposing sides of a platform of a reflector carrier;
• applying a deforming force to the spring end portions via the spring-engaging slots until a front edge of the reflector carrier passes over tops of pins projecting vertically from the base of the LED module;
• and
• decreasing a vertical separation between the front edge and the base of the LED module until the front edge is below the tops of the pins.