Not sure if this is the right area to post this, and I did try a search first, .... But I looked at the headlight seal around the left headlight on my '05 yesterday and realized it had about a two inch gap. Upon further inspection, I saw that it was broken. Is this a common problem on C6's? I've got 26K on the car. I'm assuming this will be covered under warranty.

 

First I have heard of this. I believe that if there is no impact on the light. they should cover it.

 

It is warranty if you are still within the 3yr/36,000 limits. If not, just ask for some "goodwill". See bulletin below.

The good news is the seal is now available seperately form the headlamp assembly.


Document ID# 1658195


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Subject: Headlamp Assembly Seal Torn or Cut (Replace Seal) #05-08-42-007 - (05/16/2005)



Models: 2005 Chevrolet Corvette




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Do This
Don't Do This

Replace the seal
Do not replace the headlamp assembly


Condition
Some customers may comment that the seal around the headlamp assembly is torn or cut.

Cause
This condition may be caused by a sharp edge on the headlamp assembly.

Correction
Replace the headlamp assembly seal following the procedure below:

Remove the retainer from the left and right front wheelhouse liner.
Remove the left and right valance bolts and remove the valance.
Remove the front wheelhouse liner and the brake caliper cooling duct.
Remove the lower fascia bolts and nuts.
Remove the bolts from the upper fascia.
Remove the nuts that retain the fascia to the fender.
Remove the 4 push-on pins that retain fascia to the radiator shroud.
Disconnect the electrical connector from the lamps in the fascia and remove the fascia.
Remove the electrical connectors from the head lamps and remove the 3 nuts and studs from the lamp housing.
Remove the 3 screws from the inter edge of the fender.



Lift up on the fender and remove the headlamp assembly as seen in illustration above.
Remove the 9 push-on retainers and discard the retainers.
Remove the seal from the assembly.
Check the lens for sharp edged or flashing. If found, remove with a utility knife.
The seal has a seam and it should line up with center of the DIS stamping on the lens.
Install the seal from the lens side of the lamp.
Install the 9 push-on retainers.
Lift up on the fender and install the headlamp assembly.
Install the 3 screws from the inner edge of the fender.
Tighten
Tighten fender screws to 9 N·m (80 lb in).

Install the 3 studs and nuts that retain the lamp assembly and install the electrical connector.
Tighten
Tighten the 3 bolts to 6 N·m (53 lb in).

Install the fascia and connect the electrical connectors.
Install the 4 push-on pins that retain the fascia to the radiator shroud.
Install the nuts that retain the fascia to the fender.
Tighten
Tighten nuts and bolts to 2 N·m (18 lb in).

Install the bolts that retain the upper fascia.
Tighten
Tighten bolts to 7 N·m (62 lb in).

Install the lower fascia nuts and bolts.
Tighten
Tighten the bolts to 7 N·m (62 lb in).

Install the brake caliper cooling duct and the front wheelhouse liner.
Install the left and right valance and bolts.
Tighten
Tighten the bolts to 7 N·m (62 lb in).

Install the retainer for the left and right wheelhouse liner.
Tighten
Tighten to 7 N·m (62 lb in)

Parts Information
Part Number
Description
Qty

89025130
Headlamp Seal Kit (RH)
1

89025131
Headlamp Seal Kit (LH)
1


Parts are currently available from GMSPO.

Warranty Information
For repairs performed under warranty, use:

Labor Operation
Description
Labor Time

B9749
Seal Head Lamp Assembly-Replacement
1.3 hrs*

ADD
To Replace Other Side
0.3 hr

*This is a unique labor operation number for bulletin use only with this bulletin. This number will not be published in the Labor Time Guide.




GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.
WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION


© Copyright General Motors Corporation. All Rights Reserved.


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Document ID# 1658195

 

That's good info.

 

The bad news is that GM has a repair for the problem that we hoped didn't existed.

The good news is if you want to paint you lights you would just need two of these kits.

 

Wow this is great info, thanks for posting! Lots of people want to paint their headlights so this should help them.

I wonder if it's the same procedure M6 or A6

Merry Christmas Mr. Dover.

 

I have a 2005 that has the same problem. My cause in NOT what the bulletin claims is a sharp edge. The headlight seal is not manufactured as a single cast, but it is fused or glued where the ends meet, on the forward side. On mine, the fuse let go and created a 2" gap. Not knowing if I would bring it in for a warantee freebe, and a boring winter ahead, I ordered the seal last week. Wow, $40. Not in yet. Looking at the service manual, I can see why the fender has to be removed. The seal has several slots to slip over some tabs on the headlight assembly to hold it tight. Still might do it myself. Just my experience so far. Best of luck.

 

I stopped by the dealership this morning. They thought they would have to order a complete headlight assembly until I showed them the printout from Calemaster's post. I'll have to take it back once they schedule an appointment with the bodyshop. I started to just let them replace the whole assembly, but then I got concerned about the headlight assemblies not matching exactly.

 

it's amazing. these are fellows at Chev. dealer looking at the parts catalog online and they don't know about the seal vs. the whole headlight unit. one costs X dollars and the other one costs X times what? 8, 10?

 

I actually just took a real close look at the other seal (The right one.. The one that was replaced at 1286 miles). It's splitting at the seam. Similar to the original one. The left one was not split at the seam, it's about 3 inches from the seam. I'm going to have them replace both seals while they have it apart. I already dread the experience I'm anticipating.