This procedure addresses a non-applicable repair for a 1966 Chevrolet Corvette, as HID lighting systems and ballasts were not available until decades after this vehicle was manufactured.

Warnings

Preparation

1. Verify that an aftermarket HID conversion kit is actually installed on the vehicle
2. Obtain the manufacturer documentation for the specific HID kit installed
3. Park vehicle on level ground and apply parking brake
4. Disconnect negative battery cable to prevent electrical shorts

Procedure

1. 1

   Identify HID Kit Configuration
   Locate the HID ballasts installed as part of the aftermarket conversion. Common mounting locations include behind the headlight assemblies, on the inner fender wells, or on the radiator support. Document the ballast manufacturer and model number for replacement part ordering.
2. 2

   Access Ballast Mounting Location
   Remove any trim panels, inner fender liners, or grille components necessary to access the ballast. On a 1966 Corvette, the headlights are concealed within vacuum-actuated rotating buckets; access typically requires manually rotating the headlamp buckets to the open position and removing the headlight retaining ring screws to reach components mounted behind the assembly. Mounting and access methods vary by HID kit, so refer to the kit manufacturer's instructions.
3. 3

   Disconnect Ballast Electrical Connections
   Disconnect the input power connector from the ballast (typically connected to the original headlight circuit). Then disconnect the output connector leading to the HID bulb. Note the orientation and routing of all wiring for reinstallation.
4. 4

   Remove Ballast Mounting Hardware
   Remove the fasteners securing the ballast to its mounting location. Aftermarket ballasts are typically secured with self-tapping screws, zip ties, or mounting brackets with 2-3 fasteners per ballast. Remove the failed ballast from the vehicle.
5. 5

   Install Replacement Ballast
   Mount the new ballast in the same location as the original, ensuring it is secured firmly and positioned away from heat sources such as the exhaust manifolds or radiator. Follow the kit manufacturer's recommended mounting orientation for proper cooling, as requirements vary by ballast design.
6. 6

   Reconnect Electrical Connections
   Connect the input power connector from the vehicle's headlight circuit to the ballast input. Connect the output connector from the ballast to the HID bulb. Ensure all connections are fully seated and weatherproof boots are properly positioned.
7. 7

   Secure Wiring
   Route all wiring away from moving components, sharp edges, and heat sources. Use zip ties or wire loom to secure wiring to existing harnesses or frame members, maintaining at least 6 inches clearance from exhaust components.

Reassembly

1. Reinstall any removed trim panels, headlight buckets, and bezels in reverse order of removal
2. Reconnect negative battery cable
3. Verify all mounting hardware is tight and wiring is properly secured

Verification

• Turn on headlights and verify both HID bulbs illuminate and reach full brightness within 10-15 seconds
• Check for any flickering, color shift, or delayed ignition that might indicate improper ballast installation
• Inspect all electrical connections for signs of arcing or overheating after a 5-minute test period
• Verify headlight aim has not changed and adjust if necessary using the adjustment screws on the headlight buckets

More procedures for this vehicle