Corvette C5 Dash Removal and HUD Installation
For those not familiar with heads up display, You get 9 different ways to project critical info on your windshield, like speed, Tach, gas level, oil pressure, coolant temp, turn signals, high beam indicator, shift light indicator (6 Speeds) and check gages. You can control which are displayed, adjust the height of the projection on the windshield, and the intensity. Some are shown here:
Heads up display wasn't even offered until late 99, but for those who were not fortunate enough to get this way cool option here's the directions to install it yourself. It can even be retrofitted in a 97,98, Early 99, and 01 Z06 Corvette when it wasn't even an option. Its plug and play. Any confident installer can install it within an afternoon. The factory HUD cars have a special HUD windshield that is not necessary as the projections shown above are taken on my non-HUD glass in direct sunlight. Also all 97+ C5's have the pocket for the projector, and the outline for the dash to be cut.
The following are the necessary components needed HUD to work
• HUD projector - 10279814 - (GM LIST: $1,118.82) You will have to drill 2 small holes in the dash to mount it. Even the 97,'s and 98's have the seat for the projector
• HUD Projector Bezel - 10425223 - (GM LIST: $25.52) You will have to cut a hole in the dash and the bezel is there to cover the hole. Its very easy to do though because even the 97 and 98's have the cut marked out under the dash pad. The bezel simply covers the hole.
• HUD Enabled Cluster – This is a must for a 97-99 owner that currently doesn't have a HUD enabled cluster. The cluster may be HUD ready or it could have come from a HUD equipped car. If it is only HUD ready you will need a HUD switch and 11 pin wiring harness.
• HUD Switch - Part # 12198648 (GM LIST: $124.04)
• The very important 11 Pin wiring harness which is not available from GM, you will have to find a harness, or you will have to build your own using your existing harness.
There are 2 different HUD install scenario's.
97, 98, or early 99 C5's without the HUD enabled cluster - You will need to get a late 99+ Cluster. The only way to tell whether you have the HUD enabled cluster is to remove the one you have and look for the white connector in the very back. If it doesn't already have the HUD Switch you will have to install one and find a 11 pin harness. If you need a HUD enabled cluster you will have to have it programmed with your existing mileage. I've heard ~$50 to do this, but contact your dealer. You will have to drill 3 holes to mount the projector, 2 in the plastic dash support, 1 in the aluminum column support. If you use a late 99-04 cluster you will also have to move the airbag warning light located next to the fuel gauge to the location on the Tach or else the light will remain lit al the time.
Late 99-04 C5's with a HUD enabled cluster - You will need the projector, dash bezel, switch and 11 Pin from the switch to cluster. You will have to drill only 2 holes in the plastic dash support, the third is already notched out.
Tools Necessary:
• A small assortment of flat headed screw drivers.
• Very sharp razor Blades
• Something to cut the plastic under the dash pad (Dremel tool, utility knife, angle grinder etc...)
• Something to drill mounting holes (I used a right angle electric screw driver with a 1/8" conical grinding bit)
• Torx T15 driver, or bit with compatible holder to use with 1/4" ratchet.
• 7mm socket and driver
• 10mm Socket with swivel and various extensions
• 1/4 ratchet for the 7mm socket
• Needle nose pliers
• 2 #10 rubber expansion nuts available from home improvement store (Lowe's, Home depot, Ace, Etc....)
• 2 Allen Screws for the expansion nuts. With proper Allen wrench.
• JB Quick Weld or similar to affix the bezel
• Clamps or similar to hold bezel
The install is pretty basic. If you have a roadster or coupe now is a great time to open the car up. This is also a great time to move both seats all the way back to allow your self plenty of room to work. I myself just completed this modification on my own 2000 Corvette on 8/5/03 and the pictures seen here are from my own install. These instructions are for a 2000 six speed coupe
Removing the Center Console:
1)Remove the center console. To do this you will need to open the console remove the little covers in the rear of the console to access the 2,10mm nuts. Remove these.
2) Move up towards the front of the console bin. Insert a flat headed screw driver or similar to pop off the panel with the Traction Control / Active Handling.
3) Disconnect all wiring.
4) Remove the 2, 10mm nuts under the cover, at this point you need to disconnect the fuel door switch and the rear center console is ready to be removed.
5) To remove the front half you will need to remove the shifter knob, and pull out the ash tray.
5a.) To remove the shifter knob, first pry the black shift pattern diagram. Then you will need a pair of needle nose pliers or similar to pull the key out of the shaft before being able to spin the knob off. I'm assuming the A4 has a clip in the front of the knob that has to be pulled straight out before pulling off the knob.
6) There are 3, Torx 15 screws holding the front of the console in. These are located
• 1. Under the temperature sensor panel, located to the right of the steering wheel. Pop off the bezel with a flat headed screw driver. Disconnect the air temperature sensor (If equipped with the dual climate)
• 2. to the Left of the cigarette lighter
• 3. behind the ash tray 
7) At this point the center console pulls straight off. There are a few clips that still hold it in around the radio and climate control. Don't forget to disconnect the cigarette lighter by reaching around the back and pulling the connector off. With the center console completely removed, you are now ready to work on the panel under the steering column.
Preparing for Dash Pad Removal
Start by removing the Trunk release/fog light switch bezel, with a flat headed screw driver, disconnect wires. Remove the Torx 15 screw. Remove the 2, T15 screws located up top of the instrument panel directly above the steering wheel
9) Look under the dash, towards the rear and remove the 2 T15 screws. At this point you're ready to remove the lower steering column cover. Simply pull evenly towards the steering wheel; there are 2 clips that hold near the left hand upper corner.
10) You will need to remove the radio to help reach the hazard switch to disconnect when you start to remove the dash pad. Remove the 2, 7mm screws on each side of the radio and slide it out disconnecting all connectors from the back of the radio.
11) Take a flat headed screw driver and gently pry the defroster vent grill, Disconnect the sensor on the left side and twist the sensor loose on the right, now take your 7mm 1/4 ratchet and remove the 2 screws to the outsides of the defroster
12) Remove the side pillars. To do this start from the top and pull towards the rear/center of the vehicle. Move down the pillar, there are 3 clips to completely disengage the pillars.
13) You are now ready to remove the rest of the dash pad 7mm screws. There are 2 on the top on the sides of the dash pad that were covered by the pillars. There is one on the passenger side of the dash near the hinge of the door, (look at the side of the dash with the door fully open) one near where the cluster resides on the drivers side, and the rest are visible around the stereo was
15) Once all the screws are removed from the dash pad, gently pull the dash pad away from the window. Once moved enough disconnect the hazard switch connector. This is where you're going to probably want a helper. Finish pulling the dash out of the car.
Preparing for HUD installation
16) Its now time to drill the holes for the rubber expansion nuts or whatever you decided to use. I'm sure you could also use self tapping bolts if you can managed to get space between the window and ratchet. Place the projector in into its seat pushing it all the way towards the front of the car. Mark the 2 holes with a marker or whatever you can manage to get between the window. Also mark the column support on the pre 99 cars for the 3rd mount. The 99+ cars should already have the cutout for the screw to reside in. Remove the projector and drill. Once drilled, mount the projector with whatever method you chose.
17) Once the dash pad is out, you can flip it over and see where you're supposed to cut. Cut to the very edge of the sides, and about a 1/4" from the bottom (Front of dash closest to steering wheel) to provide a step for the bezel to grip the dash pad. Cut slowly, KEEP cutting device perpendicular to cut while watching where the bezel rests. This is the most time consuming part of the install. Cut little by little constantly fitting bezel until snug. Cut the foam and pad with a sharp razor blade. TAKE YOUR TIME, you don't want to know what a replacement dash pad costs!!! (My diagram is for illustration purposes only)
18) Once you have the hole trimmed to fit the bezel, fit the bezel in place and hold it with some clamps. Make sure the bezel is flush with the rear edge of the dash (side under/closest to windshield) You can choose your own method to secure it to the dash pad. I mixed up a batch of JB Quick Weld filled the holes, glued the front tabs of the bezel, removed the clamps and was done. One of my customers cut the legs by enough to use screws into the legs.
19) While your waiting for your bezel to set you can use swap your stock 97-99 non-HUD cluster with the reprogrammed HUD enabled cluster, or to add the HUD switch and wiring harness to your HUD enabled cluster. To remove the cluster from the car with the dash pad already removed you need to remove 2, 7mm screws located just below the cluster and reach behind the cluster and pinch the large grey connector while pulling, rocking or whatever else it take to get it loose.
• 19a.) If your cluster came from a car with HUD already installed, install your new cluster and move to step 20
• 19b.) If you have a HUD enabled cluster that came from a car without HUD you will have to purchase a HUD switch from the dealer and swap it with your existing dimmer switch. If you can find a factory wiring harness, just plug it in, install and move to step 20 
Putting your Vette back together
20) Congratulations take a step back and look at the mess you've created. Maybe have a drink or two, because reinstalling it all is the easiest and fastest part.
21) Plug in the main cluster harness, and now the HUD projector harness to the back of the cluster. Key the ignition on and make sure everything works. All the gauges should do they're full sweep as well as the projection on the windshield should do similar.
• Play with the intensity, make sure it gets bright, dims, disappears...
• Cycle through the page button, to switch displayed fuel level, coolant temperature, oil pressure, also hold it briefly to switch Tach on/off cycling through the different views.
• Also move the display up and down the window to make sure everything is hooked up correctly.
• If everything appears to work correctly move on to step 22. (make sure you firmly plugged in the fuel buttons on the right if you installed the HUD switch)
22) Re-install the 2, 7mm screws holding the lower cluster in.
23) Don't forget the sensor, and wire harness you disconnected from the defroster grill. Tape them up to the defroster so they will be accessible when you reinstall the pad
24) Get your helper grab the now "HUD enabled" dash pad and move it back into place. Before pushing it all the way back toward the window, make sure to hook up the hazard switch. (Forget to do this and your turn signals will not work)
25) Re-install the various 7mm screws you removed throughout, not forgetting:
• 2 under the defroster vent,
• 2 off to the side/under the pillars,
• the one on the side near the passenger hinge area.
26) Re-install the 2, T15 screws above the cluster to dash pad
27) Re-install the side pillars by starting in the bottom, and working to the top
28) Re-install the stereo with 2, 7mm screws
29) Re-install the glove box, get all the 7mm screws, and 2, 10mm bolts in loosely before tightening everything down
30) Re-install the center console not forgetting to hook up all electrical connections
31) Re-install the shift knob/selector
32) Sit back and take a look at a job well done, hopefully there will be no mysterious screws left over.
Corvette C5 Headlight Switch-Blinker Arm Removal
This write-up will show the steps involved with removing the headlight switch / blinker arm / multi-function switch assembly, either for repair or replacement. There wasn't a good picture-rich write-up that I could find so I documented my process, and maybe it'll help somebody out.
My particular problem was that when I turn on the headlights, the taillights wouldn't work and the instrument panel would not illuminate. After removing and repairing my headlight switch, I'm fully functional once again.
Tools Needed:
-Beer of Choice (to be used whenever the heck you feel like it!)
-Torx driver or keys, for the following: T15, T20, and T25.
If you are going to open the headlight switch, add T8 to the list.
-The T25 should be a one-inch bit, OR an L-shaped key with a one-inch leg.
-1/4" open-end wrench
-Diagonal cutters (optional)
-Flat-bladed screwdriver or other thin prying device
10mm socket, 4mm socket, 7mm socket, socket wrench, and 6" extension (or equivalent set of nut-drivers)
The Procedure:
In order to get to the blinker switch, we'll be removing the knee panel that goes under and beside the steering wheel; the steering column covers; and we'll loosen the center console pieces. Here's how to do all this.
0. Turn the steering wheel such that the TOP of the wheel is facing LEFT. You'll see why in step 10.
1. First, I'd recommend loosening the center console and radio bezel. This just makes it easier/safer to remove the paneling around the steering wheel I think. For a good procedure on this, check out this guide at Vette Essentials:
Beginning with step 2 in that guide, it'll show you how to remove/loosen these pieces. That guide also parallels some of my write-up here, so you can refer to that guide for additional pictures/info. Once you have those panels removed or loose, come back here and continue on!
2. Remove the trunk release switch panel by using a flat screwdriver or somesuch to pop it out of the dash panel. It's connected to a wire which easily unplugs once you pull the switch forward.
Behind this switch is a T15 torx bolt; unscrew that and set aside with the trunk switch.
3. Next, we'll unscrew the big knee panel under the steering wheel. There are two T15 torx bolts that hold it in place... unscrew those.
4. To remove this panel after having unscrewed those two bolts, you'll need to pull TOWARDS YOU from the LEFT SIDE of the panel. There are two tight clips that you need to unsnap: (red circles are where these fasteners attach; you'll see those once you pull the panel off). The blue circle is the wire that was attached to the trunk release button.
5. When you have the left half of the knee panel loose, carefully begin to work the right half of the panel free. The HVAC sensor is attached; so mind the connecting wire (red circle in below picture). It's easily disconnected; and at that point you should be able to remove the knee panel completely and set it aside.
6. Next, let's remove the steering column covers. First we'll need to remove the bottom half. It's held on by two T20 screws, located as follows:
Once those screws are out, gently pull downward on the bottom half. It will separate from the top half... they are connected at this point solely by plastic latches (red circles) and hooks (blue circle), as shown below. With some maneuvering, the bottom piece will come free. The tricky part is getting it off from and around the tilt steering lever.
7. Unfortunately I didn't get pictures of this step; but I'll try to explain the removal of the top half of the steering column: It's held on by two torx bolts from underneath. However, these are not normal torx bolts. Instead of the torx pattern being recessed like most bolts; this star-pattern is RAISED. I don't know about you, but I don't have torx equipment for those bolts. I found that a 4mm socket does the trick nicely. A six-inch extension is preferred to reach the bolts with. There will be one bolt on each side of the steering wheel. You can see them if you can get your head underneath and look up. Unscrew these bolts, and the top half of the steering column cover will come right off.
8. Now we have the headlight switch exposed, but before we remove the thing, let's tend to the wires first. To get to them easier, I would remove the metal guard that sits behind the knee panel we removed. (It's got the styrofoam on it). You'll want the 7mm socket and a 6" extension to easily do this: Insert the socket/extension through the holes (circled in red) to get at the bolts (circled in blue). Obviously, this picture is AFTER the guard has been detached but you can still see where and how to get at the bolts.
9. The wiring from the headlight switch attaches in two locations to the car: There is a large blue connector and a small black connector. You'll want to unplug both of these. They are shown below. (To detach the blue connector... push on the small tab (circled in red) and pull apart.
You may also find that the wires from the headlight switch are cable-tied together with some other wires... If this is the case, use some diagonal cutters to cut the tie away so you can fully free the wires from the headlight switch. There is another, larger clasp/cable tie that can simply be undone without cutting it through.
10. Now we can remove the part! For this step you'll need the T25 bit/driver and the 1/4 open-end wrench. here's the part, fully exposed: Note there are TWO bolts; both T25's. The one on top is easy to get at if you tilt the steering down as far as it will go. The one facing forward, however, sits behind the steering wheel.
To remove this, we'll simply use our 1" T25 torx bit and the 1/4 inch wrench to turn it from the side: Real easy!
Get these bolts removed, and you're home free.
One word of advice... when you remove the headlight switch, you may inadvertently beep your horn. The front of the switch has a small brass pin that sticks out, that... upon touching the steel disc at the base of the steering wheel, evidently makes the horn sound off. Remember playing that game "Operation" in preschool? It's rather like that!
At this point... your switch is free of the car and ready for repair or replacement.
Corvette C6 Z06 Battery Charger Installation
Corvette C6 Z06 CTEK Battery Charger Installation
This is a quick and easy way to install the Ctek Battery Charger in the two rear compartments of your car and have 1/2 inch of the AC power cable right above your license plate. Everything is in the car, all you need to do is plug it in when you want the car to be charged.
Tools Needed
T15 Torx bit
1) Open your rear hatch and unscrew the 4 holding caps that hold the rear carpet in place.
2) There are two plastic push fasteners in the center of the carpet on the receiver for the latch. Just pull straight out and they will pull out.
3) Once the carpet is pulled back, on the right side (passenger side) of the rear portion of the tub (almost behind the first taillight to the right of your license plate), is a large rubber plug with a single wire running through it. Pop out the plug, leaving the wire in it in place.
4) Using the T15 Torx bit, remove the screw on the first taillight to the right of your license plate. Carefully pull the taillight out of the socket, being very careful not to dislodge the clip the torx screw threads into. Let the taillight gently hang on out of your rear bumper, or you can disconnect it at the plug and set it aside. Either one should be fine.
5) Next, lift open the left compartment (one without the battery), this is where your Ctek will rest. Take both the AC plug end and the Ctek plug (that will be plugging into the battery) and gently fish the full length of them under back side of the plastic bezel the surrounds the compartment. You are going to need every inch so do not leave much slack in the compartment.
6) Run both of the wires along the back of your car, behind the carpet, under the hatch receiver, the Ctek charging lead goes into the battery compartment in the same way the you routed it out of the other compartment (under the plastic surround bezel).
7) For the AC power cable, fish it through the hole where the rubber plug was. Using one hand, reach in through the taillight that you removed and grab the plug and run it down through the hole above your license plate. It is a tight fit, but will come through if you angle it correctly. Let it hang out about an inch. The rubber stopper that was in the hole will need to be cut halfway to the center, be careful not to cut the existing wire that is in the middle of it. This splice will allow you you insert the ac power cable and then put the plug back into the hole it was removed from. After you get the plug routed out of the rear of the car, go ahead and make the cut and reinsert the plug with both wires in it.
Go ahead and connect the negative and positive leads on the battery terminals. You can either remove the existing nuts (will lose power to your car) or run to your local hardware store and buy two nuts to screw right on top of the existing nut so that you will not have to disconnect battery power.
9) All done, neaten everything up…put the carpet back and you are done. You now a have a nice full self enclosed battery solution. All you need to do is plug in the car. Just do not forget to unplug it before you go on a drive
Corvette C5 Headlight Gear Rebuild
Parts needed:
brass gear kit
10mm socket
13mm socket
1/4 drive ratchet
magnetic pick-up tool
phillips screwdriver
You also need a brass gear kit (you can get this from Rodney Dickman) at www.rodneydickman.com (yes I know he sells Fiero parts...trust me he sells the gears for the C5 headlights also) you can order online or call him. he is a super nice guy and ships the stuff Priority Mail..
Ok, lets get started. Turn the headlights on or manually crank up the bad light. If you turned the lights on you can unplug the bad light and turn the other light off so as not to kill the battery.
Remove the black plastic headlight surround, 3 Phillips head screws. Now look inside the opening and you will see there are basically 5 nuts/bolts that hold the assembly in place. the following pics show the locations.
After these bolts /nuts are removed lift the assembly out and you have this.
Turn the whole piece on its side and you will see the round cover which is secured with 3 little screws:
Remove these screws and take off the cover. You will probably see something that looks like this.
Make note of how you remove things and clean all that stuff out of there so it will look like this.
Now install the new gears and replace the cover. 
Install is the reverse of removal. Plug everything back in and you should have this.
C5 Corvette LED Tailight Halo Mod
Parts needed:
- about 2' of Small gauge wire (I used 24ga stranded thin)
- (4) 5-packs of 470 ohm .5 watt resistors ($4 at RadioShack)
Tools needed:
- Voltmeter
- Wire stripper
- Solder/solder gun
- Scissors
- Phillips head screwdriver
- black marker
Here's the procedure for 1 light:
1. remove the light from the bumper
2. remove the rear panel from the light itself: remove the 4 phillips head screws and use scrape away the silicone seal from the panel on the back. NOTE: be gentle when removing the screws or you will damaged the plastic. Then slowly pry it loose with your hands (no extra leverage is necessary) It should look like this:
3. Cut the 2 white wires in the center as close to the circuit board as possible. One is positive and one is ground. To find out which is which, strip about 1/4" off each, go back to the car and plug it back into the socket. Turn on the parking lights and use the voltmeter to identify the positive and ground. use the sharpie to label the ground wire.
4. You'll see 4 wires going to the sides of the light: red, black, yellow and orange. each of the 4 LEDs gets its own pair of wires (there are 2 per side) Cut the wires on both sides as close to the circuit board as possible and strip 1/4" insulation from them. The polarity is as follows:
red and orange are power wires
yellow and black are ground wires
twist the black and yellow ends together and solder. Install resistors on the ends of the orange and red wires. Use your 24ga wire to join the power wires on both sides and the ground wires for both sides. Then connect them to the main power/ground white wires you labeled earlier.
5. Make sure your connections are soldered and insulated with electrical tape then test. Make sure your socket is installed in the correct direction.
Created by Radio Flyer from the Corvette Forum