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Cutting Map Light Hole on ABS Headliner

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Old May 29, 2024 | 10:48 AM
  #1  
ryguy32789's Avatar
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From: Chicagoland
Car: 1984 Z28
Engine: 305 HO
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Cutting Map Light Hole on ABS Headliner

I recently bought an ABS headliner from somebody on FB Marketplace. Brand is unknown. It seems that the hole is cut for the base dome light, and is not big enough to accommodate the map light/dome light combo. Is my only way to get this fit to cut it? Or should I make a slot for the front metal tab to slip into? What's the best way to make this fit?

Also, I feel really dumb asking this, but I can't for the life of me get that plug to disconnect from the dome light, and I'm afraid of breaking it off. Is there some trick to release the clips?







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Old May 29, 2024 | 07:43 PM
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soloc4's Avatar
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From: Lake Stevens, WA
Car: 84 Z28, 92 C4 suspension F&R, ABS
Engine: 408 LS2, CNC LS3 heads, Comp Cam
Transmission: Magnum F, RTX clutch, Tick shifter
Axle/Gears: DANA 44 IRS, Tru Trac, 3:73 gears
Re: Cutting Map Light Hole on ABS Headliner

Yes you will have to cut the opening larger (wider and longer at the front). It is a delicate balance since the margins are small. Big enough to clear the metal housing, but not too large so the plastic housing covers the hole. This applies to the sides as well as the front where the tab clips to the headliner. I have the same light in my 84 hardtop and I used an ABS headliner as well. I cut the board before I cover it. If you still have the original headliner, you can use it as a template for the hole. I did not have that option. Good luck and let us know how it turns out.
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Old May 29, 2024 | 09:29 PM
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ryguy32789's Avatar
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From: Chicagoland
Car: 1984 Z28
Engine: 305 HO
Transmission: T5
Axle/Gears: 3.73
Re: Cutting Map Light Hole on ABS Headliner

Thanks - unfortunately I bought the car without the original headliner as well. Guess I'll proceed carefully!

Do you know how that light unclips from the wiring harness?

Last edited by ryguy32789; May 29, 2024 at 09:38 PM.
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Old May 29, 2024 | 10:34 PM
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soloc4's Avatar
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From: Lake Stevens, WA
Car: 84 Z28, 92 C4 suspension F&R, ABS
Engine: 408 LS2, CNC LS3 heads, Comp Cam
Transmission: Magnum F, RTX clutch, Tick shifter
Axle/Gears: DANA 44 IRS, Tru Trac, 3:73 gears
Re: Cutting Map Light Hole on ABS Headliner

Originally Posted by ryguy32789
Thanks - unfortunately I bought the car without the original headliner as well. Guess I'll proceed carefully!

Do you know how that light unclips from the wiring harness?
I remove the 2 map sockets to give more room to grab the plug on both sides. The lock should simply release and it will pull right off. Be gentle, it is 40 year old plastic.
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Old May 29, 2024 | 11:52 PM
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ryguy32789's Avatar
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From: Chicagoland
Car: 1984 Z28
Engine: 305 HO
Transmission: T5
Axle/Gears: 3.73
Re: Cutting Map Light Hole on ABS Headliner

Originally Posted by soloc4
I remove the 2 map sockets to give more room to grab the plug on both sides. The lock should simply release and it will pull right off. Be gentle, it is 40 year old plastic.
Where is the separation point? Does the entire yellowish plug come off the light, or does the plug split in two? I see two little ears that clip into the light housing that look like they can squeeze together, but even with pliers they are stuck in there.
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Old May 30, 2024 | 06:59 AM
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soloc4's Avatar
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From: Lake Stevens, WA
Car: 84 Z28, 92 C4 suspension F&R, ABS
Engine: 408 LS2, CNC LS3 heads, Comp Cam
Transmission: Magnum F, RTX clutch, Tick shifter
Axle/Gears: DANA 44 IRS, Tru Trac, 3:73 gears
Re: Cutting Map Light Hole on ABS Headliner

Originally Posted by ryguy32789
Where is the separation point? Does the entire yellowish plug come off the light, or does the plug split in two? I see two little ears that clip into the light housing that look like they can squeeze together, but even with pliers they are stuck in there.
Yes, the entire plug comes off the housing. There is a corresponding male connector attached to the housing and you want to remove the female connector that you see. The two ears that you see are indeed the positive lock for the connector, squeeze those and pull straight up and off. You may have to wiggle it a bit to loosen it up since it has been on there awhile. While you are in there, it would be a good idea to change the bulbs. I upgraded all three to LED.
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