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Old 10-27-2016, 06:26 PM   #1
Ironhorse
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'99 Tahoe Headlight Removal Problem

Our '99 Tahoe (188K) recently begin a problem of the driver's side low beam not always coming on with the switch turned on. A tap on the lens and it comes right on, high beams work fine. I suspect maybe a loose bulb in the connector? Passenger side, no problem. Utube video shows simple removal of the two 5MM bolts down thru the top of the radiator support going into the assembly and then remove the composite headlight assembly. Sounds and looks simple I know.

NOT so much simple as shown in the video. Both 5MM bolts removed, headlight assembly loose in the grill but absolutely refuses to exit the grill. I can move it out more from the inboard side than the outboard side but just refuses to come out. EVERYTHING being plastic I hate to get forceful with it. Shined a light all around the H/L assembly and can not see it is hung up anywhere but seems to be stuck on the outboard side.

Anyone run into this problem before? Not sure what the problem is, did I mention EVERYTHING is plastic !!
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Old 10-28-2016, 02:55 AM   #2
izzy_Britton
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Re: '99 Tahoe Headlight Removal Problem

I am not 100% for certain. BUT i believe that there are NO BOLTS holding the headlamp into the truck. there should be 2 pins that are about 6-8 inches long that either slip down from the top thru holding holes and lock into place with a 1/4 turn or go side to side. I dont remember if it is GMC that is vertical and chevy is horizontal locking pins or vise versa...

I will look in the morning when i get to the shop and let you know how mine is.

-Izzy
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Old 10-28-2016, 02:56 AM   #3
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Re: '99 Tahoe Headlight Removal Problem

of coarse the question is...

classic (88-98) or new (99-03/99-06) ???
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Old 10-28-2016, 03:00 AM   #4
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Re: '99 Tahoe Headlight Removal Problem

https://www.youtube.com/watch?v=JhA1w_IFV4Y
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Old 10-28-2016, 07:42 AM   #5
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Re: '99 Tahoe Headlight Removal Problem

That is the very same video from Utube that I watched. Removed both of the 5MM bolts as mentioned which did loosen the headlight in the grill but it refuses to come out. As I mentioned in first posting, I am working on a '99 Tahoe so not sure why the headlight will not come out as in the video.
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Old 10-29-2016, 03:25 PM   #6
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Re: '99 Tahoe Headlight Removal Problem

I don't remember if it's outer or inner edge, but one edge is easier to pull out than the other. Yes, it is all plastic but there is enough give to get them out.
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Old 10-30-2016, 05:24 PM   #7
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Re: '99 Tahoe Headlight Removal Problem

Headlight still refuses to exit the grill area. After taking the two bolts loose from the radiator support the headlight is loose in the mount area but "hangs up" in the back when try to remove it. Right side will come out a bit further than the left but still hangs up. ? ?
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Old 10-31-2016, 06:13 AM   #8
95 S_Trucker
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Re: '99 Tahoe Headlight Removal Problem

Wiggle and pull.

If you still cant get them out, just take out the grill. Remove the turn signal lenses. Remove the 5 7mm screws. Remove the corer lamp light sockets. Release the 2 clips(1 under each turn signal lens) and the grill will come off.

GMT400=88-98 board

GMT800=99-06 board
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Old 10-31-2016, 09:30 AM   #9
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Re: '99 Tahoe Headlight Removal Problem

Ironhorse, when I get home I'll pop the hood on roommates truck and pull one of his, take a few pics or video. Are you working on a Chev or GMC? Arguably the same, just slight different grille fitment/shape.

95 S-Trucker, don't forget the clip in the dead center between grille & filler panel. I'm getting good at that one with a long 3/8" extension.
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1983 GMC High Sierra 2500, 4x4, RC/LB, 400 S.B., SM-465, NP-208, Corporate 10 bolt & 9.5" 14 bolt
1996 GMC Sierra SLE 3500 DRW, 4x4, EC/LB, Vortec 454, NV-4500, BW-4401, AAM 925 & AAM 1050
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Old 10-31-2016, 09:39 AM   #10
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Re: '99 Tahoe Headlight Removal Problem

Thanks for the replies, working on a '99 Chevrolet Tahoe. After looking at it again I am considering having to pull the grill. Can't do that for awhile as wife drives it to work all week. Maybe this weekend.
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Old 11-02-2016, 12:26 AM   #11
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Re: '99 Tahoe Headlight Removal Problem

I dunno what happened to my post the other day so i will just ask again

You keep saying 5mm bolts. are you actually unscrewing bolts that go into the radiator support?

OR

are you referring to the "L" shaped pins that you twist 1/4 turn and slide out?

if your talking about the unscrew type bolts then your doing it wrong. these trucks have a "L" shaped pin that is about 6 inches long that holds the headlight assembly in place.

it might be helpful to the rest of us if you could snap a pic or take a quick short video and post em so we can maybe help guide you better. just a thought. I now have 3 of these trucks and have had about 7 so far that have all used the L pins. some are horizontal and some are verticle (GMC vs. CHEVY).

there is a 'headlight mount panel' that BOLTS to the radiator support and then the headlamps are pinned to that.

please clarify, BOLTS (unscrew) or PIN (1/4 twist and pull/slide)

-Izzy
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Old 11-02-2016, 05:06 AM   #12
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Re: '99 Tahoe Headlight Removal Problem

It's a gmt400 truck and this whole thread should be in the 88-98 section. Not the 99-06. The op has long screws/studs that he's removing. The headlight should slide out of the hole with little effort.
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Old 11-02-2016, 10:33 AM   #13
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Re: '99 Tahoe Headlight Removal Problem

Not sure why this should be in the 88-98 section, working on a '99 so I posted in the '99 - 2006 section. Minor point. I am actually removing (2) two threaded bolts with a 5 mm head, about 6'' long. They go down thru the top of the radiator support thru a tab with a hole in it on the back side of the headlight assembly. H/L just refuses to come out, will have time this weekend to try removing the grill as mentioned. Wife drives it back and forth to work so time is limited to do such during the week.
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Old 11-02-2016, 04:28 PM   #14
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Re: '99 Tahoe Headlight Removal Problem

Sorry, truck wasn't available for me to get pics of the other day, hope to tonight.

This thread does belong in the 88-98 section. The 1999 Tahoe is a GMT-400 platform vehicle, which is generally referred to as 88-98. GM and their overlap. They did it 88-91 with squarebody & GMT-400 overlap, and did it again in 99-02 (05 outside of north american market) with GMT-400 & GMT-800 overlap. The year ranges on this forum are a vague guide, it is more important to match your bodystyle than follow what year they list.
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1983 GMC High Sierra 2500, 4x4, RC/LB, 400 S.B., SM-465, NP-208, Corporate 10 bolt & 9.5" 14 bolt
1996 GMC Sierra SLE 3500 DRW, 4x4, EC/LB, Vortec 454, NV-4500, BW-4401, AAM 925 & AAM 1050
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Old 11-04-2016, 02:03 AM   #15
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Re: '99 Tahoe Headlight Removal Problem

Quote:
Originally Posted by 95 S_Trucker View Post
It's a gmt400 truck and this whole thread should be in the 88-98 section. Not the 99-06. The op has long screws/studs that he's removing. The headlight should slide out of the hole with little effort.
Quote:
Originally Posted by izzy_Britton View Post
of coarse the question is...

classic (88-98) or new (99-03/99-06) ???
maybe a MOD can move the thread?
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Cream Puff - LS'd Square - Slow going on the back burner
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Old 11-05-2016, 01:08 PM   #16
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Re: '99 Tahoe Headlight Removal Problem

Okay, back in working order on the H/L now !

Had time today with wife not needing the Tahoe for work, removed the 4 ( 2 each headlight) 5MM threaded bolts and then 4 small screws along the top of the grill at the radiator support and the 5th screw at the brace in the center of the grill. This allowed enough movement to pull the grill slightly forward and was able to remove the composite headlight bucket.

Checked the connections at the back of the H/L, all seemed good, turned on lights, no light until I lightly tapped the bulb housing making sure I did not touch the bulb itself. Light came on, switched inside H/L switch on-off several times, all is good. Put everything back together, turned on the switch, no H/L.

Pulled everything back apart, took the bulb down to local O'reilly Auto, told them the problem, "you got a bad connector, not making a good connection" Sounds reasonable since the bulb looked good at the filament from what I could see. Bought a connector, went back home, spliced it in, turned on the H/Ls, NOPE ! Tap the H/L, light comes on. Back down to O'reilly Auto, "gimme a bulb for low beam '99 Tahoe 9006 PN." Got the bulb, went home, installed it, turned on the H/Ls, light is ON. Turned switch on/off about 6-8 times all good.

Found out the grill housing had been jammed in at an angle, the composite
H/L was wedged in too far in the opening. Sorry for the loonngg post but all is good now and I STILL hate all the plastic in today's vehicles.
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