Headlight Housing Installation
I can give you some suggestions as I had to bang my head a few times :banghead: recently when putting mine back together after rewiring. Make sure you refer to the previous link:
http://clubs.hemmings.com/clubsites/oana/tech/Headl.pdf
for examples of the figures I refer to. Figures 4 and 6 must NOT be attached to the headlight bucket when you situate the headlight housing into the body!
1. Be sure to clean and relube the lower rotator cuff (fig 4.). Slide this piece onto the rotator pin that is attached to the body of the car.
2. Be sure that the bracket (fig 5.) IS already bolted to the headlight housing. The bracket in (fig 5.) is NOT :banghead: the way to manipulate the headlight housing into the body!
3. There are three bolts (fig 6.) that hold the rotator assembly to the bracket in (fig 5.) THIS is how you manipulate the headlight housing into the body, with the three bolts out.
4. Before going any further be sure to tape up the edges of the headlight bucket and the headlight housing with tape.... If you do not, you WILL scratch and chip your paint!
5. Once you have the lower rotator cuff (fig. 4) in place, the taping of the body and headlight housing is done, and the three bolts and nuts to (fig. 6) are placed nearby, carefully slide and manipulate the headlight housing into the body. I would suggest sliding the TOP of the headlight housing BACK into the body and then lowering the bottom of the headlight housing into the front of the body.
6. At this point you can reattach and lightly tighten the two bolts that hold the rotator cuff (fig.4) in place.
7. Be sure to pull the headlight wiring through the center of the bracket (fig. 6) and reattach that bracket using the OUTER 2 bolts and holes to the bracket in (fig.5). You can tighten these two bolts at this time.
8. Now comes the difficult part, you must reattach the bracket in (fig. 6) with it's 3 bolts to the 3 holes in the rotator mechanism that is attached to the body. The problem is that there is limited space in this area. Be careful not to overtighten yet.
9. Once you have the 3 bolts (fig. 6) and the 2 bolts (fig.4) in place check to see that you have equal clearance between the BODY of the car and the Headlight Housing. If you need to adjust the healight housing forward or backward the bolt in the CENTER of (fig. 4) rotator cuff will do that for you.
When you think you have everything lined up, test your headlight housing movement either by rolling them by hand and/or with the lever in the car. Once you are pleased with the alignment, then tighten the 3 bolts in (fig. 6) and the two outer bolts in (fig.4).
Anyone feel free to add info, and forgive me if I forget something.
Neil
Thanks for everybody's input. I got both buckets in today with no damage to the new paint job. The first one was tough, but the second one went in real easy. Thanks again.
