I’ve disassembled both headlight housings on my SII FHC, making a dry run prior to purchasing and replacing the sealed beam units with halogen unsealed units. Taking the units apart I expected that individual pieces might require replacing and I was right. I will need the headlamp seat + rim, pin adjuster kit, new rubber seals. I’d like to retain the domes, original to the car with stampings. My plan is to remove, clean and repaint the housings. What I’m uncertain of is what is the method to remove the rubber plug sealing off the wires? (pic below) Do I just jimmy it and pull it through? Thanks!

 

Use a flat blade screw driver to pry under the plug and push it through to the back. You will need to push in two places to get it all the way through. The good news is the rubber looks so new and pliable that it will not disintegrate in the process.

 

Hey MrVette, thank you, that’s exactly what I ended up doing! And an update, after consideration I elected to order replacements for the entire assembly; buckets + seal, plug + pigtail & grommet, headlamp bowl & halogen lamps (unsealed).