Procedure for replacing a single headlight bulb on a 1966 Chevrolet Corvette with 327ci V8 engine, including removal of the headlight bezel and sealed beam unit.

Warnings

Tools required

Parts

• Sealed beam headlight unit × 1 — 7-inch round sealed beam, Type 1 or Type 2 depending on configuration

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off headlight switch and remove ignition key
3. Allow headlights to cool if recently operated (5-10 minutes)

Procedure

1. 1

   Access the headlight assembly
   Open the hood and identify the headlight assembly from the front of the vehicle. The 1966 Corvette features rotating (flip-up) headlights driven by electric motors; ensure the headlights are in the open (up) position. If the headlights are closed, turn the headlight switch to the ON (headlight) position to rotate them up, then disconnect the battery or pull the headlight motor fuse to keep them up safely while working.
2. 2

   Remove the headlight bezel retaining screws
   Using a Phillips screwdriver, remove the 5 screws that secure the chrome headlight bezel trim ring to the headlight bucket. These screws are located around the perimeter of the bezel. Keep these screws in a safe location for reinstallation.
   ℹ️Do not confuse the bezel retaining screws with the headlight aim adjustment screws, which are typically located at the top and side of the headlight assembly.
3. 3

   Remove the headlight bezel
   Carefully pull the chrome headlight bezel trim ring away from the headlight bucket and set it aside in a safe location where it will not be scratched.
4. 4

   Remove the sealed beam retaining ring screws
   Using a Phillips screwdriver, remove the 3 screws securing the sealed beam retaining ring. These screws pass through slots in the retaining ring and thread into the headlight bucket. Do not remove or adjust the headlight aim adjustment screws.
5. 5

   Remove the sealed beam retaining ring
   Lift the sealed beam retaining ring off the headlight assembly and set it aside. This ring holds the sealed beam unit in place against the headlight bucket.
6. 6

   Remove the sealed beam unit
   Carefully pull the sealed beam headlight unit forward approximately 2 inches from the headlight bucket to access the electrical connector on the rear of the unit.
7. 7

   Disconnect the electrical connector
   Disconnect the electrical connector from the rear of the sealed beam unit by firmly pulling it straight off. Outboard (dual-filament Type 2) units use a 3-prong connector; inboard (high-beam-only Type 1) units use a 2-prong connector. Note the orientation of the connector for proper reinstallation.
8. 8

   Install the new sealed beam unit
   Connect the electrical connector (2-prong for inboard Type 1 units, 3-prong for outboard Type 2 units) to the rear of the new sealed beam unit, ensuring it is fully seated. The connector is keyed and will only fit in one orientation. Position the sealed beam unit into the headlight bucket, aligning the locating tabs on the unit with the slots in the bucket.
9. 9

   Reinstall the sealed beam retaining ring
   Place the sealed beam retaining ring over the sealed beam unit, aligning the screw holes. Install the 3 retaining ring screws through the slots and thread them into the headlight bucket. Tighten the screws snugly in a criss-cross pattern, but do not overtighten as this can crack the sealed beam lens.
10. 10

    Reinstall the headlight bezel
    Position the chrome headlight bezel trim ring over the headlight assembly, aligning the screw holes. Install the 5 bezel retaining screws and tighten them evenly in a star pattern to ensure the bezel seats properly and evenly against the headlight bucket.

Reassembly

1. Ensure all screws are tight but not overtightened to prevent damage to chrome trim
2. Verify headlight bezel is flush and evenly seated around its entire perimeter

Verification

• Turn on the headlight switch and verify the new headlight illuminates properly
• Check both low beam and high beam operation
• Verify the headlight retraction mechanism still operates correctly (turn headlights off and verify they retract)
• Inspect the headlight bezel to ensure it is properly seated and all screws are secure

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