GM Truck Headlight Wiring Sockets

[aotte1]

Found these GM sockets replacement on EBay, that fit my 1983-86 trucks ( probably other years too). They allow you to remove original headlight wires from old/broken sockets, and install original headlight wires in new sockets. Have done two sockets so far. Use a Home Depot Husky #2.0 straight screw driver, from a small screw driver set, and small hammer. Place the replacement socket w/wires in open vice, with socket on top, wires hanging down through opening. Lightly tap screw driver to release wire. The original do in truck. For me, most will not release by hand. Will post a couple of photos of process soon.
Below is the eBay listing used. Posted this thread because they allow you to replace sockets with original wire/clip. Hope this helps.


GM Truck Headlight Wiring Sockets- For Low & High Sealed Beam Bulbs- 4 pcs- #044

Note: The wire is released from socket by pressing wire tab closed, photos showing tab and its location soon.

IMPORTANT!——see posts below for better information on Packard part numbers and terminal connectors purchasing!!

Photos:
- first two show original and new replacement from this set;
- third and forth the screw driver used; and
- last new socket w/wires removed.

[aotte1]

Second set photos

- one and two show placement of screw drive, before light hammer tapping;
- second show better screwdriver placement on 2 wire, the 3 wire socket center wire is opposite the two outer wires;
- three and four show completed new socket with original wires; and
- five is replacement as received.

[aotte1]

Last photos

- first is original sockets after living in AR it whole life, along with wild animals chewing some;
- second is terminal kit that did not work; and
- last is eBay listing.
New note added, see post below for other option on purchasing original type white terminal connectors. Thanks to Hatzie for information on original Packard part numbers.

[hatzie]

OE headlight sockets take Packard 59 terminals

1209344030 is the Packard 59 extractor. It's got a purple handle. The Packard 56 extractor has a green handle. I picked up several Delphi Packard extractors in some yard sale tool boxes. You can make them with a grinder out of peanut butter screwdrivers. I've found the little green handle Xcellite precision screwdrivers work as well cuz the shaft of the screwdriver is'nt any larger than the sides of the flat tip.

02973215 is the Packard 59 terminal sized for 16 to 18 AWG

2965810 is the three terminal black Packard 59 connector shell for the H4 sealed beams.
6288471 is the natural color three terminal Packard 59 connector for the H4 sealed beams

6288472 is the natural color Packard 59 connector for two terminal sealed beam headlights

[aotte1]

Hatzie,

Thanks for adding more useful information.

Note: Mouser Electronics sell both the 2 and 3 terminal connectors, 6288472 and 6288471 in white.
These are made by the company that purchased Delphi-Packard, maybe APTIV?
I just purchased some of both. Will report once received.

Les

[aotte1]

A few photos of the replacement headlight terminals being made, to replace those eaten by desert animals. First photo shows new #59 terminal before connection, along with after crimping. First time using new tool, still learning where to place terminal in tool.
Note: tried single use cheaper tool, did not work for this process. The tool used is expensive, however, works.

[aotte1]

A few more. Showing crimping tool with removable die. Used two different dies for whole process. Uses die “C” for these. Other two photos show non insulated butt connectors packaged used for connection to original wire harness. Last two photos in no order, show completed terminal that connects to headlight. Next photo will show butt connectors.

[aotte1]

Connection of repair terminal to wire harness, with butt connector. These are copper tinned connectors. Used same tool for these connections with different die.

Again thanks to “Hatzie” for information provided.