This procedure covers the removal and replacement of the headlight assembly on a 1970 AMC Rebel Machine, including sealed beam unit, retaining ring, and adjustment of headlight aim.

Warnings

Tools required

Parts

• Sealed beam headlight unit (7-inch round) × 1 — Use OEM specification or Wagner/GE replacement
• Headlight retaining ring × 1 — Use OEM specification if damaged

Preparation

1. Park vehicle on level surface and turn off all lights
2. Open hood and secure with prop rod
3. Identify which headlight assembly requires replacement (inner or outer on dual headlight system)
4. If adjusting aim after replacement, mark existing headlight position on wall or use headlight aiming screen at 25 feet

Procedure

1. 1

   Remove headlight bezel trim
   Locate and remove the Phillips head screws securing the chrome headlight bezel trim ring. The 1970 Rebel uses a decorative bezel that must be removed first to access the headlight retaining ring. There are typically 4-5 screws around the perimeter. Set bezel and screws aside.
2. 2

   Remove headlight retaining ring screws
   Identify the headlight retaining ring screws (typically 3 screws evenly spaced around the sealed beam). Do NOT remove the headlight adjustment screws, which are typically located at 12 o'clock and 3 o'clock positions and are attached to springs. The retaining ring screws will be smaller and do not have springs behind them. Remove only the retaining ring screws using a Phillips screwdriver.
3. 3

   Remove headlight retaining ring
   Carefully pull the headlight retaining ring away from the headlight bucket. The ring may have tension from the sealed beam unit behind it. Rotate slightly if needed to clear the adjustment screws, then remove completely.
4. 4

   Pull sealed beam forward and disconnect wiring
   Gently pull the sealed beam headlight unit forward out of the headlight bucket. Reach behind the unit and locate the three-prong connector attached to the back of the sealed beam. Firmly grasp the connector body (not the wires) and pull straight back to disconnect. Support the sealed beam unit to prevent it from falling.
5. 5

   Inspect headlight bucket and adjustment mechanism
   With the sealed beam removed, inspect the headlight bucket for corrosion, damage, or debris. Check that both vertical and horizontal adjustment screws move freely and that their springs are intact. Clean any dirt or corrosion from the bucket and adjustment mechanism. Verify the rubber grommet seal (if equipped) on the headlight bucket is in good condition.
6. 6

   Connect new sealed beam unit
   Remove the new sealed beam from its packaging, handling it by the edges only. Locate the three-prong connector from the wiring harness. Align the connector with the terminals on the back of the new sealed beam unit, ensuring correct orientation (the connector will only fit one way). Push firmly until the connector is fully seated on the sealed beam terminals.
7. 7

   Install sealed beam into bucket
   Carefully position the new sealed beam unit into the headlight bucket, ensuring the unit is properly oriented with the word 'TOP' or alignment tab at the 12 o'clock position. The sealed beam should seat against the adjustment pads in the bucket. Route the wiring connector through the bucket opening without pinching.
8. 8

   Install retaining ring
   Position the headlight retaining ring over the sealed beam unit, aligning the screw holes with the mounting points in the headlight bucket. Ensure the ring does not interfere with the vertical and horizontal adjustment screws. The retaining ring should sit flush against the sealed beam rim.
9. 9

   Secure retaining ring screws
   Install the retaining ring screws and tighten in a cross-pattern to ensure even pressure on the sealed beam. Tighten screws snugly but do not over-tighten, as this can crack the sealed beam glass or distort the retaining ring. Verify the sealed beam is held firmly without excessive pressure.
10. 10

    Test headlight operation
    Before reinstalling the bezel, turn on the headlights and verify the new sealed beam illuminates properly on both low and high beam settings. Check that the beam pattern appears correct and that there is no flickering or intermittent operation. Turn off headlights before proceeding.
11. 11

    Reinstall headlight bezel trim
    Position the chrome headlight bezel trim over the retaining ring, aligning all screw holes. Install the bezel screws and tighten evenly in a cross-pattern to ensure the bezel sits flush and even around the headlight assembly. Do not over-tighten, as chrome bezels can distort.
12. 12

    Adjust headlight aim
    If headlight aim adjustment is needed, locate the vertical adjustment screw (top) and horizontal adjustment screw (side) on the headlight bucket. Turn the vertical screw clockwise to raise the beam or counterclockwise to lower it. Turn the horizontal screw to adjust left or right. Proper aim should be verified using headlight aiming equipment or by projecting the beam on a wall at 25 feet with the vehicle on level ground. The center of the beam should be slightly below and to the right of the horizontal and vertical centerlines of the light.

Reassembly

1. Ensure all bezel screws are tightened and the chrome trim is properly seated
2. Verify headlight retaining ring screws are secure but not over-tightened
3. Check that wiring connector is fully seated and secure behind the sealed beam

Verification

• Test headlights on both low and high beam settings to confirm proper operation
• Verify headlight beam pattern is correct with no dark spots or unusual patterns indicating misalignment
• Check that headlight bezel is secure and properly aligned with vehicle body trim
• If multiple headlights were replaced, verify all units illuminate with matching intensity and color temperature
• Road test vehicle after dark to confirm adequate illumination and proper beam aim

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