1st Generation Specific (1979-1985) 1979-1985 Discussion including performance modifications and technical support sections

Headlight cover removal

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Old Feb 5, 2023 | 03:51 PM
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murben's Avatar
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Headlight cover removal

Any tips on getting the screws out that hold the headlight cover in place? I'm trying to get in to swap over to the putco relay harness, but so far 2 of the screws have stuck so bad that they heads are now stripped out. I'm hesitant to drill them, because the one is the back, inside screw near the hood and I don't know how to get to it without risking scratching the hood.
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Old Feb 5, 2023 | 05:12 PM
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The metal top does not need to come off. Take the top black rubber shield off the top of the light motor. There is a little **** on top to twist. Put the lights up. Remove the screws on each side of the light that hold the black plastic. Now it needs to be removed but it's a little hard. Gently pull one side forward working each side little by little. Now remove the chrome ring from around the light. Three more screws. Make sure to remove the correct screws and not the aiming ones. Twist the chrome ring. Reach around and disconnect the light plug. It's a littler stubborn.

Twist the headlight motor **** again and lower the light until the PUTCO plug fits over the header panel where the factory light wiring is. Lower the light enough to pass the plug in. Make sure to route it so it does not get pinched.
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Old Feb 6, 2023 | 08:29 AM
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Thanks for this! I'll give this a shot after work today. Sounds much better than trying to get those cover screws off.
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Old Feb 8, 2023 | 12:59 AM
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Mine are stripped too.. And i do want to remove them to fix chipped paint :/ stupid screws.
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Old Feb 8, 2023 | 12:06 PM
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I've encountered those particular screws and they can be difficult. A couple years ago I purchased some Vessel brand screwdrivers with their "jaws fit" technology. The phillips drive is manufactured to the same JIS standard specs that the fasteners are.

https://www.motorcycle.com/ask-mo-an...-phillips.html

Plus, they are serrated which helps them to grip the screw and reduce stripping out the head. Kind of pricy, but quality tools are worth it in my opinion. This screw driver has become my favorite tool in the box.



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Old Mar 1, 2023 | 06:07 PM
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Originally Posted by Banzai
I've encountered those particular screws and they can be difficult. A couple years ago I purchased some Vessel brand screwdrivers with their "jaws fit" technology. The phillips drive is manufactured to the same JIS standard specs that the fasteners are.

https://www.motorcycle.com/ask-mo-an...-phillips.html

Plus, they are serrated which helps them to grip the screw and reduce stripping out the head. Kind of pricy, but quality tools are worth it in my opinion. This screw driver has become my favorite tool in the box.


Good tools are worth every penny . Same with art products. I will pick one of those up since my mustang also has a few stubborn screws that always end up getting stripped .
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