How to Replace Chevy Astro Van Headlights

Written by jody l. campbell
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There are two types of headlights that may appear on your Chevy Astro Van depending on the year. Some earlier models came with the old-fashioned sealed beam units and the newer versions of the Astro came with the composite halogen bulb replacements. Each type of headlight replacement has different instructions and take different tools, but chances are you have either lying around your house and can replace them yourself.

Skill level:

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Things you need

  • Ratchet and 10 millimetre socket
  • Magnetic tipped Phillips head screwdriver
  • Replacement bulb(s)

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    Replacing the Astro's Halogen Headlights

  1. 1

    Open the bonnet to the Astro Van to replace the composite halogen-type headlight.

  2. 2

    Remove the two 10mm bolts on top and the other two on the left and right side of the headlight assembly.

  3. 3

    Gently pull the headlight assembly forward away from the vehicle.

  4. 4

    Determine which bulb is bad. Low beam are on the outside closest to the fenders and high beams are on the inside.

  5. 5

    Turn the bulb holder counterclockwise from behind the headlight assembly until it releases. About 1/4 turn should do.

  6. 6

    Unplug the wire to the headlight bulb and remove the old bulb.

  7. 7

    Insert the new bulb through the holder and replace the wire. Test the lights now by turning them on to make sure the headlight is working.

  8. 8

    Insert the new bulb into the headlight assembly. Be careful not to touch the glass bulb of the new light. Turn clockwise until it locks into place.

  9. 9

    Remove the tools and close the bonnet.

    Replacing the Astro's Sealed Beam Unit Headlights

  1. 1

    Remove the four headlight bezel screws from the bezel of the sealed unit type headlight with a magnetic Phillips head screwdriver. Be sure to remove only the bezel screws (two on top and two on bottom) and do not turn any headlight adjuster screws (one top centre, one side centre).

  2. 2

    Pull the sealed beam unit out and unplug the wire harness from behind it.

  3. 3

    Plug the new headlight into the wire harness and reinsert into the headlight cavity.

  4. 4

    Test the headlight to make sure it's working properly.

  5. 5

    Replace the bezel and the bezel screws.

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