Headlight Adjuster replacement
Thread Starter
Pro
Joined: Feb 2004
Posts: 653
Likes: 5
From: Florida
Headlight Adjuster replacement
Hi everyone, 
My Headlight adjuster shaft has snapped off after turning slowly. GM has decided to make the shaft out of aluminum which is soft and is prone to snapping off while turning.
I was able to get a new Adjuster assembly from a guy on Ebay. The trick is the actual install.
My question is, has anyone been able to replace the adjuster without removing the actual Lens?
I'm at a point where I have twisted the keyed groove to unlock from base, then turned the adjuster by hand to allow it to be free and floppy from the base assembly. I have attached pics of the adjuster which is attached by to my headlight assembly via a Press fit plastic ball joint. When I pull towards my body it seems like I'm using a lot of pulling force to pop out the ball of the adjuster from the plastic base. I don't want to damage the tiny plastic Ball holder so I stopped. If I were to give it some more force and it does pop out of socket. I'm concerned on what force it will take to pop the new adjuster back in.
Thanks everyone for the help.
My Headlight adjuster shaft has snapped off after turning slowly. GM has decided to make the shaft out of aluminum which is soft and is prone to snapping off while turning.
I was able to get a new Adjuster assembly from a guy on Ebay. The trick is the actual install.
My question is, has anyone been able to replace the adjuster without removing the actual Lens?
I'm at a point where I have twisted the keyed groove to unlock from base, then turned the adjuster by hand to allow it to be free and floppy from the base assembly. I have attached pics of the adjuster which is attached by to my headlight assembly via a Press fit plastic ball joint. When I pull towards my body it seems like I'm using a lot of pulling force to pop out the ball of the adjuster from the plastic base. I don't want to damage the tiny plastic Ball holder so I stopped. If I were to give it some more force and it does pop out of socket. I'm concerned on what force it will take to pop the new adjuster back in.
Thanks everyone for the help.
Last edited by Lotus77777; Mar 26, 2014 at 11:23 AM.
Supporting Vendor
Joined: Sep 2007
Posts: 11,216
Likes: 178
From: Pensacola Florida GO GATORS!!! www.rlsebring.com www.c6c7vette.com
St. Jude Donor '17
Don't try to remove the rod or you will have an expensive mess when the retaining clip breaks.
Looking at your picture leave the adjuster arm pointing down. Turn the adjuster till you back the arm/housing off the rod. If the adjuster is easy it will back off. If it is difficult it will turn the rod and you'll have to get some needle nose vise grips clamped on the rod to hold from spinning along with the adjuster.
Once removed take the replacement and push it onto the rod in the same position and turn the arm in the opposite direction to thread it onto the rod. There's a flat spot on the rod and inside the threaded housing that they have to match. They usually will in this position. If not the housing will stop. Just turn the arm/housing toward the outside of the light and turn the arm again until the rod passes through the back side of the adjuster housing.
Have about an 1/8 inch of rod sticking out of the adjuster, push the housing back into the cam opening and turn the adjuster arm back into normal position. put the high beam bulb and boot back on then adjust the arm till about a quarter to 3/8" of the rod is sticking out. The headlight will be very close to the correct angle. Adjust to the correct height once installed back in the car.
Good Luck!
Looking at your picture leave the adjuster arm pointing down. Turn the adjuster till you back the arm/housing off the rod. If the adjuster is easy it will back off. If it is difficult it will turn the rod and you'll have to get some needle nose vise grips clamped on the rod to hold from spinning along with the adjuster.
Once removed take the replacement and push it onto the rod in the same position and turn the arm in the opposite direction to thread it onto the rod. There's a flat spot on the rod and inside the threaded housing that they have to match. They usually will in this position. If not the housing will stop. Just turn the arm/housing toward the outside of the light and turn the arm again until the rod passes through the back side of the adjuster housing.
Have about an 1/8 inch of rod sticking out of the adjuster, push the housing back into the cam opening and turn the adjuster arm back into normal position. put the high beam bulb and boot back on then adjust the arm till about a quarter to 3/8" of the rod is sticking out. The headlight will be very close to the correct angle. Adjust to the correct height once installed back in the car.
Good Luck!
Thread Starter
Pro
Joined: Feb 2004
Posts: 653
Likes: 5
From: Florida
Don't try to remove the rod or you will have an expensive mess when the retaining clip breaks.
Looking at your picture leave the adjuster arm pointing down. Turn the adjuster till you back the arm/housing off the rod. If the adjuster is easy it will back off. If it is difficult it will turn the rod and you'll have to get some needle nose vise grips clamped on the rod to hold from spinning along with the adjuster.
Once removed take the replacement and push it onto the rod in the same position and turn the arm in the opposite direction to thread it onto the rod. There's a flat spot on the rod and inside the threaded housing that they have to match. They usually will in this position. If not the housing will stop. Just turn the arm/housing toward the outside of the light and turn the arm again until the rod passes through the back side of the adjuster housing.
Have about an 1/8 inch of rod sticking out of the adjuster, push the housing back into the cam opening and turn the adjuster arm back into normal position. put the high beam bulb and boot back on then adjust the arm till about a quarter to 3/8" of the rod is sticking out. The headlight will be very close to the correct angle. Adjust to the correct height once installed back in the car.
Good Luck!
Looking at your picture leave the adjuster arm pointing down. Turn the adjuster till you back the arm/housing off the rod. If the adjuster is easy it will back off. If it is difficult it will turn the rod and you'll have to get some needle nose vise grips clamped on the rod to hold from spinning along with the adjuster.
Once removed take the replacement and push it onto the rod in the same position and turn the arm in the opposite direction to thread it onto the rod. There's a flat spot on the rod and inside the threaded housing that they have to match. They usually will in this position. If not the housing will stop. Just turn the arm/housing toward the outside of the light and turn the arm again until the rod passes through the back side of the adjuster housing.
Have about an 1/8 inch of rod sticking out of the adjuster, push the housing back into the cam opening and turn the adjuster arm back into normal position. put the high beam bulb and boot back on then adjust the arm till about a quarter to 3/8" of the rod is sticking out. The headlight will be very close to the correct angle. Adjust to the correct height once installed back in the car.
Good Luck!
Thank you Thank you
Your intricate knowledge has saved me from cracking the inside of my housing. I don't post much on this forum, but having a community of friends that helps you when your stuck is so amazing.
Supporting Vendor
Joined: Sep 2007
Posts: 11,216
Likes: 178
From: Pensacola Florida GO GATORS!!! www.rlsebring.com www.c6c7vette.com
St. Jude Donor '17
Glad I could help. 
I want to say thank you 100%. I have been thinking about this for a long time. I'm so glad I didn't keep pulling it. For some reason I had it in my head that the shaft and the adjuster assembly was one unit and maybe had some type of retaining clip inside that stopped the shaft from twisting all the way out so I never attempted that until now when you said that it comes out. I just did exactly what you said and in 10 minutes my new adjuster assembly is back on my headlight.
Thank you Thank you
Your intricate knowledge has saved me from cracking the inside of my housing. I don't post much on this forum, but having a community of friends that helps you when your stuck is so amazing.
Thank you Thank you
Your intricate knowledge has saved me from cracking the inside of my housing. I don't post much on this forum, but having a community of friends that helps you when your stuck is so amazing.
