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Old 12-19-2003   #3 (permalink)
kwilford
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Join Date: Mar 2002
Location: Calgary, Alberta, Canada
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Real Name: Keith Wilford
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Good advice by nobody (that sounds kinda' weird!). Once those bolts are broken off, it is a major PITA to fix a headlight mechanism. But I just had to figure a way to do it, and after some (many) failures, here's the best way I can suggest.

First, here's a photo of the front of the mechanism, with the small bolts shown. What makes it hard to fix is that they are not only an odd size (M5 x 0.8 with an 8 mm head versus the standard 9 mm head), they are also metric grade 10.9. Which is equivalent to an SAE Grade 8 bolt, so they are HARD. And damn difficult to drill out. What I learned was you can't drill them out from the front, as the remainder of the bolt will be pushed out the bottom of the hole and jam in the mechanism.
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Keith Wilford
working on my '71 GT and '75 SportWagon
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