I tear down all the dashboard + center gauges preparing to do few things
1. To change the headlight switch
2. To change the inst' light to blue SMD bulbs.
3. To change the Ammeter to Voltmeter.
4. To fix the Radio.
I started with the Headlight switch, First the old Headlight switch have 8 contacts and the new Headlight switch 68-77 that I bought have 7 contacts.

Old Headlight switch 1968


The problem is the new Headlight switch behave differently from the old one, when you pull the **** one step in the old one it turn on the marker lights but in the new one it turn on the marker lights + Low beam front light, second step the behave the same but in the new one the Low beam front light already lights and the foot dimmer change between high & low beam.
So I bought also 67 Headlight switch that have 8 contacts.
I check it and it behave like the old Headlight switch but doesn’t have the vacuum switch.
I also checked my 72 Headlight switch it has 7 contacts, it behave OK like the old 68 Headlight switch.

New Headlight switch 67 + 68-77



I open up the new Headlight switch 68-77 + the new Headlight switch 67 And I saw that the inside contacts are deferent.

New Headlight switch 68-77 + 67, inside contacts


I change between them the metal cover with the vacuum switch & also the white part in the front of the switch it's deferent.
Now I have new Headlight switch with 8 contacts + vacuum switch.


I bought two Headlight switch 68-77 both from Willcox both have the same problem the Headlight switch 67 I bought from CC.
Did any one had this problem when he change his Headlight switch
Avner

 

No. I bought a repro switch a few years back; it was a direct fit and works fine. No changes needed.

 

Same here, got mine from Keene parts

 

You have the WRONG switch! The 7-terminal switch with the vacuum switch you show, is for 1974 & up Corvettes. The earlier switch is different internally as you've indicated. The early and later switch are not interchangeable.

 

Good to know & learn new thing.
Willcox advertize Headlamp Switch 68-77 #370022, so it's wrong.
http://willcoxcorvette.com/product_i...oducts_id=1529

Thanks
Avner

 

You are correct. Willcox is listing the switch incorrectly. There are 3 DIFFERENT and NON-interchangeable Corvette headlight switches from 68-82. They are: 68-73, 74-77 and 78-82 switches.

 

Great. I just ordered that part for my '69. I won't be able to check if it's the same until this fall (car in storage). Right now I have a NAPA headlight switch w/o vacuum as a temp fix and have to use the vacuum override to open them up.

Willcox, what say you?

 

The original part and production number for the headlamp switch for 1968-1974 was 1995166. You can id an original headlamp switch by the presence of the part number 166 stamped in the back side of the metal bracket opposite the vacuum tubes.

This part was replaced in July 1974 by part number 1995191. 1995191 was the last production part number for the switch from July 1974 until the switch discontinued around 1996.

Both original 1995166 and 1995191 had 7 terminals (I have both in my hand right now) and will post pictures later today.

The GM application for this switch was 1968-1977 as shown in the 1953-1977 GM parts book Rev. 09-1977.

68·77· Y • 1995191 1 N.L SWITCH

and from the 1971 parts book rev. Dec 1971 you'll find this.
68-72 Corvette.. . . . . . . . . . . . . . . . 1995166

Now there is a difference between the original 1995166 and the 1995191. There was a grounding tab added to the metal bracket on the bottom for 1995191 and the rheostat was slightly different.

Again.. you can ID an original 1968-1974 switch by the presence of 166 stamped on the back.. and both switches have 7 electrical terminals in the black portion of the switch.

Avner.. what part number is stamped on the back of the switch you removed from the car... I know of no other switch from 1968-1977.



Willcox

 

Willcox:
The 1968 Headlight switch stamp is 166 but it has 8 contacts.
I checked also with the 1972 Headlight switch stamp is 191 w/7 contacts both behave the same, the switch that I bought from you behave deferent like I explain in first.
Thanks
Avner

 

I've never seen a 166 with 8 terminals. There is no reason the switch sold to you should not install and function perfectly.

Willcox

 

I have a 68 with the 166 switch. It is exactly like avner's switch. I can not seem to find an exact duplicate used or new. My rheostat is broken so I have not dash lights. Any information would be greatly appreciated.

 

There are somethings that just aren't reproduced the correct '68 switch is one, the '68 **** is another. If you check Ecklers they list the **** as '68-'71 and '77. Not correct!

Here is the correct '68 switch #166 and it does have 8 contacts.

 

Interesting Rick

Wonder what the extra terminal was for... I've not had anyone install the other switch and have a problem.. Investigation time.. again..

I've got a stack of the 166's used.. I'll have to look at them a bit closer. Is there a wire in the connector for this terminal?

Ernie

 

Hi Ernie,

I'll have to find my old harness and check the connector, I'll post what I find but with our luck it's probably got something to do with the damn '68 wipers!

 

Is it just 68 owners that get the humor in this...myself being one?
Hilarious!
Once again Wilcox right in there on our behalf.

 

I've learned over the years to just sigh.
I'm going to need a new HL switch soon as well. My dash dimmer is dead - only full on available. I have a very late 68, so I might have a "normal" switch. I hope.

-W

 

DZ......... 68's had damn wipers too? so does my 69 !!!!

 

Am in the process of working on a '68 Vette. Plenty issues.... Nice to have headlights!
Dash lights don't work, nor do headlighhts.
What was the outcome of the 7 and 8 terminal headlighht connector?
I have a 7 terminal, but appears to be an aftermarket, so may have been an attempt to solve headlight issue by previous owner.
When I look at the connector (plug), there is no female connector for what appears to be terminals 3 and 7.... I can take a picture of the wires and connector tomorrow. Wire colors are: Red, White, Blue, Brown, Orange and Green. There is also Black for the ground terminal.

 

Am also working on identifying 2 loose connectors (plugs). Would appreciate any aha, that's blah blah blah.
Would also appreciate which 1968 Corvette manuals are best for wiring, suspension etc.

My project is of a '68 Convertible. Originally had a 427, now 454. As with every Vette, there is a story.... One previous owner had cancer, was probably great guy, just maybe not the most mechanically inclined.... Hope the car served as an outlet for him!

Appreciate any insight.

 

If you have a good headlight switch, except the dimmer rheostat does not work, you can easily replace just the rheostat. I have done it. However they keep burning out, even on the original ones. I added a solid piece of flat sheet copper to bridge the two correct terminals, after having a couple rheostats burn out. Your dash lights are on bright then.
I also made a 68 headlight switch **** by using the **** off of the correct cigarette lighter ****. Lou.