01
The headlamp housings are made of fiberglass for 1963
models only; the 1964-’67 housings are die-cast metal.
Here, a door is shown with the primary components associated
with its rotating function, including seals, pivot balls and the
pivot ball sockets. The socket on the right side of the image
shows the black headlamp position activation switch. The
longer shaft on each housing mounts on the inboard side of the
body opening and engages the electric motor.
02
For the sake of illustration clarity, we’re showing the
installed sequence of the pivot components prior to
installation, because the tight confines under the Corvette nose
make it difficult for easy photography. This is the outer shaft of
the housing, which faces the wheel opening on the body. The
sequence starts with a seal and support washer against the
headlamp support housing, a washer, a felt seal for the pivot
ball, the pivot ball itself, with the larger end pointed toward the
bearing support socket, and the bearing support pivot socket.It’s a good idea to re-tap and lubricate
all of the threaded holes in the body and
bearing supports to ease assembly in the
harder-to-reach areas.
Lubrication of the pivot shafts, spherical
bearings and bearing support housings
prior to assembly is critically important
to their ease of function and long-term
operation.
It’s also important to properly position
the rubber seals, support washers and felts
that are part of the pivoting components
to prevent dirt and other contaminants
from entering the bearings. That not only
minimizes stress on the headlamp motors,
but also ensures proper movement and
durability.
Mask off the edges of the body openings
to prevent paint nicks; and have a second
set of hands to help hold the doors in place
during the initial assembly process.
It is infinitely easier to perform this
project with the bumpers, grille and hood
removed.
Finally, the installer should be prepared
to tighten and loosen the various fasteners
numerous times before the doors are
properly positioned and aligned. Again,
patience with this process is as important
as a deep 3/8-inch socket.
03
After the housing is properly
positioned, a collar with a set screw
is installed on the short shaft. The set
screw will be tightened on the shaft after
the housing is properly centered in the
body opening.04
On the inner-side, longer shaft,
the sequence is the same: seal,
washer, ball seal, pivot ball and socket;
although this support socket includes
the position activation switch for the
headlamps.05
Establishing the
lateral position of
the headlamp housing is
accomplished by adjusting
the position of this Y-stop on
the inner pivot shaft and the
previously mentioned collar
on the outer shaft. Along with
determining the lateral (side-
to-side) housing position,
the Y-stop also supports the
adjustment bolts that limit
the housing’s rotation and
activates the headlamp
position switch.VETTEWEB.COM 31