Question about 2002 Chevrolet Corvette

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One of the headlight flipper/cover will not activate. Can push down on manual openner and auto will statrt working but only temporarily.

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Hello, my name is Ben. You probably know by now this is a common problem with Corvettes. Chevrolet uses a cheap plastic gear to raise and lower the headlights and it is prone to wear out. Most likely the gear has a broken or worn tooth and will need to be replaced. Several after market companies sell a new brass gear to replace the cheap plastic one. If you are handy, you should be able to rebuild the headlight assembly on your own, or if you search you can someone to rebuild it for you. Good luck and I hope this has helped you, Ben.

Posted on Jul 03, 2010

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Posted on Jan 02, 2017

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How to replace the side marker/position light bulb on the driver side? I can't even get to it because i can't get the light housing off!


The Headlight Assembly is not difficult to remove but you do need to be careful NOT to pull on the Headlight Assembly and break the clips

1. Open the S60's hood and locate the pin that is behind the headlight assembly of the bulb that needs replacement. The pin has a handle on the top. Pull the pin straight out of the headlight assembly.

  • 2. Push on the back of the headlight assembly until it comes out the front of the S60. There is an electrical connection on the back of the assembly; unplug the connection.

  • 3. Press on both clamp on the assembly. The clamps are on either side. Push them in together so that the cover releases.

  • 4 Uncover the bulb by pulling on the small plastic cover that covers each bulb. Push the visible wire aside. Pull the bulb straight out.

  • 5 Push a new bulb in and push the metal wire back over it to secure the bulb in the assembly. Push the covers back on.

  • 6. Reconnect the electrical harness to the assembly and push the assembly back into place. Push the retaining pin all the way back down into place.
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    Hello,
    Follow the process below to replace your headlight:
    • Prop open your hood and locate the release lever for the headlight assembly, the lever is approximately 2 inches under the two upper mounting bolts that hold the fender in place.

    • Press down on the release lever and then push it back up. Pull the headlight assembly forward and slide it out of your Beetle.
    • Unplug the electrical connector from the backside of the assembly. Look toward the top part of the backside of the assembly for a black plastic tab. Push down on the tab and pull the headlight cover up and out.
    • Pull the retaining clip off of the old bulb and remove the old bulb from the assembly by pulling it straight out. Align the bulb correctly with the headlight assembly by matching the marked tabs on the bulb with the raised notches on the assembly. Set the bulb inside the assembly, pushing it down carefully.
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    The headlights do not activate automatically, in the auto mode, at night or with minimal daylight. However the running lights will activate in the auto mode. A new dash light switch was installed without...


    The light sensor to control the automatic headlamps is located on the dashboard. This sensor is suppose to activate running and headlamps. I would suspect the problem is a relay to operate the headlamps if the car uses a seperate relay in the automatic mode. I'm assuming the headlamps work in manual on/off. FYI... The auto mode does not control the fog lamps.

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    Try this:
    1. Before you try removing the headlight housings, check for a blown fuse first, since the headlight circuits on these cars are fused. The fuse is located on the regular fuse panel inside the car, on the left side of the dashboard behind the removable cover.
      Well, since there are no visible screws anywhere around, how do I get the headlight out? It’s not that hard at all.
    2. Open the hood. Locate the seam between the nosepiece and the front fender (either side). Go up between the first two fender mounting bolts and look down a few inches. See a small knob sticking out at you? That is a release lever for the headlight assembly. Push in on it slightly and pull all the way up as far as the lever will go.
    3. Now push on the headlight from behind with one hand and be prepared to catch the assembly with the free hand from the front. It may take a bit of a push because there is some gooey adhesive between the headlight and the fender.
    4. Once you have the headlight out, pull the connector off the back of the housing and take the headlight somewhere where it is easy to work on. Put it on a pillow or something soft so you don’t risk scratching the lens.
    5. There is a black plastic cover on the back of the housing. See a tab on it? Push on this tab and pull the cover down to expose the bulbs.
    6. There is a metal spring clip that holds these bulbs in place. Undo this and the bulb will fall out. Take out the new bulb and compare it with the one you are replacing. Make sure the wattage is correct, since they are both H1 bulbs. Never touch the glass part of the bulb itself with your fingers.
    7. Use the soft cloth to handle the bulb if needed. Line up the tabs of the bulb base with the slots in the reflector housing and drop the bulb in. Put the spring clip back on and make sure the ends of the clip are in securely. Put the bulb cover back on. Now is the time to clean up the mess around the fender where the headlight mounts. Remember seeing that nasty-looking goo seep out from around the rubber seal on your headlights? That’s the adhesive I was talking about earlier.
    8. Take the adhesive remover on the paper towels and remove this stuff from the fender before putting the headlight back in. Don’t remove all of it from behind the headlight itself, as it is there to keep excess amounts of water from getting behind the headlight. Just remove enough to where it won’t make a mess anymore. A little wax around the mounting area on the fender will detail things out nicely.
    9. Position the headlight up to the fender. Push on the wire connector. Line up the tabs on the headlight assembly to the slots in the headlight housing in the fender and push the whole thing in. Sometimes things won’t line up on the first try, but keep trying. The headlight should go up against the fender fairly easily.
    10. Once you get it to this point, grab the release lever, push all the way down, and lock the headlight assembly into place.

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