Complete removal and replacement of both headlight assemblies on a 1966 Chevrolet Corvette C2, including removal of chrome bezels, sealed beam units, and adjustment rings.

Warnings

Tools required

Parts

• Sealed beam headlight unit (7-inch round) × 2 — Use OEM specification or aftermarket equivalent (H6024 halogen or H6014 standard)
• Headlight adjustment ring × 2 — Use OEM specification
• Chrome headlight bezel/trim ring × 2 — Use OEM specification
• Headlight retaining ring screws × 6 — Use OEM specification

Preparation

1. Park vehicle on level surface and turn off all lights
2. Allow headlights to cool completely if recently used (minimum 10 minutes)
3. Rotate hideaway headlight doors to full 'up' position using manual override knob located in engine compartment if doors will not raise electrically
4. Prepare clean work area and lay out shop towels to protect chrome trim pieces during removal

Procedure

1. 1

   Mark headlight aim position
   Before removal, use masking tape to mark the current position of the adjustment screws on both the horizontal and vertical adjustment mechanisms visible behind the headlight bucket. This will help preserve your existing headlight aim. Mark the screw position against the adjustment ring for reference.
2. 2

   Remove chrome headlight bezel
   Locate the 3 Phillips head screws securing the outer chrome bezel/trim ring. These screws are evenly spaced around the perimeter of the bezel. Remove all 3 screws and carefully pull the chrome bezel forward away from the headlight assembly. Set bezel face-down on clean towel to prevent scratching.
3. 3

   Remove headlight retaining ring
   With the bezel removed, you will see the headlight retaining ring with 3 Phillips head screws (these are separate from the adjustment screws which should not be disturbed unless re-aiming). Remove the 3 retaining ring screws by turning counterclockwise. Note that adjustment screws typically have spring tension; the retaining screws do not. Remove the retaining ring.
4. 4

   Disconnect sealed beam unit
   Pull the sealed beam unit forward approximately 2 inches until the wiring connector at the rear of the unit is accessible. Grasp the plastic connector body (not the wires) and pull straight back to disconnect the 3-prong connector from the sealed beam terminals. Remove the old sealed beam unit from the headlight bucket.
5. 5

   Inspect headlight bucket and adjustment mechanism
   With the sealed beam removed, inspect the headlight bucket for corrosion, debris, or damage. Clean any dirt or corrosion from the bucket using a shop towel. Verify that both vertical and horizontal adjustment screws move freely. Check the condition of the rubber weather seal or spring clips in the headlight bucket that will seat against the new sealed beam.
6. 6

   Install new sealed beam unit
   Without touching the glass lens surface, orient the new sealed beam unit with the three terminal prongs facing toward the rear of the headlight bucket and the embossed 'TOP' marking at the 12 o'clock position. Push the 3-prong connector firmly onto the terminals at the rear of the sealed beam until it seats completely. Guide the sealed beam unit into the bucket, ensuring it seats properly against the adjustment mechanism pivot point and the spring or rubber sealing surface.
7. 7

   Install headlight retaining ring
   Position the headlight retaining ring over the sealed beam unit, aligning the three screw holes. Ensure the sealed beam remains properly seated in the adjustment mechanism. Install the 3 retaining ring screws and tighten in a star pattern (skip one hole between each pass) to ensure even pressure. Tighten screws snug but do not overtighten as this can crack the sealed beam lens.
8. 8

   Reinstall chrome bezel
   Position the chrome bezel over the headlight assembly, aligning the three screw holes with the threaded mounting points in the headlight housing. Install the 3 bezel screws and tighten evenly in a star pattern until snug. Verify the bezel sits flush against the body panel with no gaps.
9. 9

   Repeat for opposite side
   Repeat steps 2 through 8 for the opposite side headlight assembly, following the same removal and installation sequence.
10. 10

    Test headlight operation
    Turn the ignition to the 'on' position and activate the headlight switch. Verify both headlights illuminate on low beam, then test high beam operation. Check that both sealed beam units light evenly without flickering or dark spots. Turn off headlights.

Reassembly

1. Verify all 6 chrome bezel screws (3 per side) are installed and tightened
2. Verify both headlight connectors are fully seated with no exposed terminals
3. Clean any fingerprints or marks from chrome bezels using appropriate chrome cleaner

Verification

• Turn headlights on and verify both units illuminate properly on low and high beam
• Visually inspect both headlight assemblies to ensure chrome bezels are flush and properly aligned with body panels
• Check that headlight aim has been preserved by comparing adjustment screw positions to the masking tape reference marks made during disassembly; perform full headlight aim procedure if necessary using proper aiming equipment or the 25-foot wall projection method
• Verify hideaway headlight doors retract and extend properly with headlight switch operation (if vehicle is equipped with functional vacuum system)

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