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