C3 headlight door actuator seals

[Robert Holmes]

I need to replace the seals on my '68 headlight actuators, can someone suggest the best way to approach the task? It isn't immediately obvious what I need to disassemble to do the job. They are otherwise working, so I'm hoping I can avoid extra effort!
Thanks
Bob Holmes

[Joe L.]

Re: C3 headlight door actuator seals

Bob-----

This is actually a quite simple job----one of the few such jobs that you will encounter on a Corvette.

You don't actually even have to remove the actuators from the car, although, in some respects, this might actually simplify the seal replacement. The actuators are relatively easy to remove from the car if you choose to do so.

Anyway, all you have to do is to remove the headlight actuator rod from the headlight mechanism. This is done by first removing the cotter pin and then removing the clevis pin which retains the actuator rod end to the assembly.

Next, remove the actuator rod end (it's a large cast "eyelet" piece) by simply screwing it off the rod. Then, pull off the actuator rod boot (the bellows-like, black rubber piece). Finally, pry out the black rubber seal from the housing using a small screwdriver or similar tool.

Personally, I find that removing the actuator(s) from the car makes the job of removing and re-installing the new seal a lot easier. You want to make sure that you get this seal in right or you'll end up with a leak and poor actuator performance.

[Robert Holmes]

Re: C3 headlight door actuator seals

Thanks Joe!
Bob Holmes

[Patrick H.]

Caveat.

One thing Joe forgot (although I've mentioned it before) is that removing the actuators on a car with air conditioning is VERY difficult given the 2 inches or so less space ahead of the radiator. If your car has AC (Joe's doesn't) then you're best off doing this repair with the actuators in the car.

Patrick

[George D.]

Re: Caveat.

One other problem you may encounter is getting the adjuster (cast piece that Joe mentioned) off the threaded rod if they have been on the car a long time. I would apply some penatrating oil before you start. You can use a vise grip (with some protection) to hold the rod while unscrewing it. However, I think the best way is to take them off the car prior to changing the seal. As previously mentioned if the car has AC it is rather difficult to get them past the condensor. When removing them from my 69 AC car I put a thin piece of card board over the condensor to protect it.