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I have a 99. I'm trying to find the proper replacement plug for the HEADLIGHT ADJUSTER HOLE. I bought one from Corvette Central I thought it was the one with the three notches. I measured the hole and it is about 2 and a 1/8 inches in diameter. The hole has no notches. Can anyone tell me what I'm looking for and where to find one? Thanks!
If you find the right plug, you might want to use a little black RTV to install them. If you need to adjust the lights, you can easily remove the whole bezel.
1997 - 1999: Service Bulletin: Loose or Missing Headlamp Door Bezel Plug
Subject: Loose or Missing Headlamp Door Bezel Plug (Install New Bezels and Plugs)
Source: Chevrolet Dealer Technical Service Bulletin
Number: 99-08-42-005
Models: 1997-99 Chevrolet Corvette
This bulletin is being revised to add the 1999 model year, update part numbers, service procedures, labor operations and labor times. Please discard Corporate Bulletin Number 83-82-07 (Section 8 - Chassis/Body Electrical)
Condition
Some customers may comment that the plastic plug that covers the headlamp aiming adjustment screw on the inboard side of the headlamp door bezel is loose or missing.
Correction
Two different size plugs have been used in production. Early production 1997 vehicles used a plug with a diameter of 24 mm (15/16 in), while later 1997 vehicles and all 1998 and 1999 vehicles use a larger 54 mm (2 1/8 in) diameter plug. Both size plugs have been replaced by a new design plug and, therefore, will no longer be available
I have a 99. I'm trying to find the proper replacement plug for the HEADLIGHT ADJUSTER HOLE. I bought one from Corvette Central I thought it was the one with the three notches. I measured the hole and it is about 2 and a 1/8 inches in diameter. The hole has no notches. Can anyone tell me what I'm looking for and where to find one? Thanks!
ive noticed that the headlight adjuster hole plug was missing on mine that i bought a few weeks ago from a dealership. told the dude and he ordered me another one.
problem is, the (correct one) that doesnt have the notches doesnt even fit very well either! its soo loose, if you dont put silicone around it or tape to hold it in place, it will just fall out.
what im going to do is find some rubber door trim (the ones that careless people fit around the outsides of their doors so they dont mark up cars next to them when they bang them against other vehicles at walmart upon getting out of their own) and cut-to-fit around the inside of the adjuster hole itself. that should trim off just enough slack-space around the edge of the hole to ensure a tight fit.
the correct adjuster hole plug has a little arrow denoting where to place a screwdriver into when you need to get at the adjustment mechanism itself - so that tells me right there that its supposed to fit snug.
google - 'rubber edge trim' and you will see what i mean. its also black so it will go perfectly with the black side of the headlight assembly
Caplugs sent me one as a sample for no charge and I RTVed it in the housing
I got the right Caplug from their website as a sample for free. I have RTVed both sides to the housings with RTV. If you need to work on the headlights take out the 3 screws as suggested by another member.
I also have a 99 and I lost two sets.... One from corvette central and also the newer one from the chevy dealership... They both worked great for two minutes, before flying off..
Ebay has both types of headlight adjuster hole plugs. Notched or smooth. Search - C5 Corvette headlight adjuster hole plug and will show you all. Do refine with lowest price first. I picked up for 6.95 each with free shipping.
I also have a 99 and I lost two sets.... One from corvette central and also the newer one from the chevy dealership... They both worked great for two minutes, before flying off..
I hate to open such a old post but I recently saw I lost one of these Plugs on my '99 Coupe. I remember replacing this once or twice on the drivers side of the car since I purchased the car in 2010. I even Black Siliconed it around the edge from the outside. I guess I should of taken the bezel off and glued it in from the inside and will now once I can locate one or 2 to have one back up at a reasonable price. Corvette Central has them for $4.10 each. I have no problem with the price but I am not going to pay $10.99 for shipping. Maybe I will try Lowes or the Home Depot next for a CA Plug. Not trying to be cheap. I have no problem with the price its the shipping that gets me. These pieces are basically light weight plastic. You can very easily put them in a regular envelope and mail 2 out for less then a dollar to NJ. I know shipping is expensive today but to make a Homerun on Shipping bothers me for a product like this. I had to say something about this. Any suggestions?
I'm using the top of a sea salt grinder, fits perfectly and caulked it in. Spent countless hours trying to find a rubber plug for electrical boxes, etc, with no avail. Got tired of buying the oem that just don't stay in, even caulked, plus they are not cheap for what they are. So for now, I have my solution. By the way, there are two oem sizes, I have the older smaller size.
jdmvette Saw those on Ebay. They don't look like the factory one on the opposite Side of my '99 Coupe. Mine doesn't have slots. The sizing is supposedly different also. My research shows me those fit the newer 2000 up C5's. The '99 and down look like the ones in this photo at this link at Central. https://www.corvettecentral.com/c5-9...rly-for-445024 and below in my attachment. I would like a match for the other side if at all possible.
I decided to go another route this time. Since I have purchased these before and they flew off even after securing them with some Black RTV and pushing them in I ended up purchasing a assortment of 50 different sizes on Amazon. The '97-99 required one 2-1/8" and the kit has them up to 2" with a few to spare of the same size. The 2" is the correct size for 2000 C5's on up. I just can't stomach paying $10.99 to have one shipped even at $4.10 each which to me was a fair price for the part alone. There isn't much difference between 2" and 2-1/8" that I am going to guess at least (6) 2" come in the Assortment. A bead of Black Silicone RTV on the inside this time of the bezil no one will know the difference and if it falls off again which I doubt this time I will have plenty of Spares to rig up even stronger if need be. All the Feedback on what they are selling people to fit has plenty of complaints no matter where I read the feedback that they don't fit right and fly off anyway. So even if I purchased one that supposedly fits I will need to glue it in anyway. For around the shipping price for one I will have 50 Various sizes I may need to use on something else eventually and I will have the kit by Monday. I would have to wait another week for the Expensive $10.99 Shipping to get it to me if I chose to buy one from the Corvette Supplier I had mentioned. Sorry but I don't like being taken advantage of. $10.99 is making a Home Run on someone just for shipping a almost weightless plastic plug.
04-26-2010, 06:55 PM
Headlight adjuster hole plug ?
Spent countless hours trying to find a rubber plug for electrical boxes, etc, with no avail. Got tired of buying the oem that just don't stay in, even caulked, plus they are not cheap for what they are. So for now, I have my solution. By the way, there are two oem sizes, I have the older smaller size.
