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  • Headlight Door Actuator - Remanufactured ~ 1969 Mercury Cougar - 42502
  • Headlight Door Actuator - Remanufactured ~ 1969 Mercury Cougar - 42502
  • Headlight Door Actuator - Remanufactured ~ 1969 Mercury Cougar - 42502

Item #: 42502

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MSRP:$329.99
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Price: $329.85
    Cost: 26388
    Earns: 330
    Bonus: 0

    Availability:

    Out of Stock - Unknown

    At the moment, we don't expect to have any actuators in stock in the near future, so we suggest taking a look at our Electric Headlight Conversion kit here.

    ALL ACTUATORS COME WITH A TWO YEAR WARRANTY.

    For core refund, please send core with a copy of your receipt. If you would like us to hold your order until we receive your cores or for us to restore your cores, please contact us.

    Just like our 1967 - 1968 units these have been opened up and meticulously re-manufactured to better than new standards.

    Better than NOS? That may seem like a pretty lofty claim but in actuality these 1969 - 1970 actuators were made to pretty low standards compared to the earlier 1967 - 1968 units.

    These actuators are carefully opened and closely examined. All damaged parts are discarded and replaced with good used and new parts. These cans had a very light black Zinc coating from the factory that rusted rapidly. Black Zinc is affected by heat and did not hold up well on these low cost stamped steel units. We have chosen to coat them with a heat resistant (up to 500 degrees Fahrenheit) manifold paint that closely resembles the original color. They are carefully coated inside and out.

    All rubber parts are replaced with better than new, top quality parts. It is our goal that you never have to replace this unit again.

    This is the dust boot. Its function is to keep contaminants off the shaft. It also keeps the white lithium grease in place on the shaft to ensure the upper shaft seal stays lubricated.

    Originally the diaphragm plates were attached to this shaft by a heat peened stud. To remove the plates we grind off the stud. To reinstall the plates we drill, tap and reattach the plates with a stainless steel screw. These shafts were not the best quality from the factory so we send them in to be stress relieved. This process changes the composition of the steel which insures our screw will never come lose and the shaft is very unlikely to become worn or easily bent. This step is overkill but it is our intent to make these truly better than NOS.

    *NOTE* Do not attempt to force "rock hard" old used hoses on the nipples. You will void the warranty. When installing good used hoses or our new hose kits you will want to apply a small amount of white lithium grease before installing the hoses on to the nipples.

    The retaining ring is a new replacement done in the correct clear Zinc.

    As carefully as possible, the retaining ring is removed. When replaced we try to crimp them in just like you would see from the factory. If your unit is not crimped in four places at the top but rather the lip is evenly pressed over the ring then what you have is a later dated service replacement part. Notice the four very small spot welds.

    This picture is of the inside of the upper half of the actuator, notice the very small spot welds that hold the two mounting studs in place to the right and left. Make sure and do not over tighten the mounting studs as these spot welds will easily break.

    The diaphragm plates are redone in the correct clear Zinc. Heavily rusted plates are always discarded.

    The rubber parts have incredible elasticity and strength. This cost much more money to have them done this way but the results are fantastic. We hope that our customers will realize the value they are getting when they purchase this unit. This is not a quickie refresh, these units have been painstakingly renewed by a true craftsman with an incredible eye for detail and a real sense of pride in workmanship. The hidden headlamps on the early Cougars were one of their trademarks that set them apart from the more common Pony Cars of the day. I personally take pride in seeing my 1969 Cougar sit week after week in the garage with the eyelids remaining closed. A 100% tight system will remain closed for months. In addition a tight system will be able to have the headlight doors opened and closed without starting the car even if it has been parked for a prolonged period. This actuator is almost always one of the culprits in keeping your system from being 100% free of vacuum leaks. We are very proud to be able to offer this quality solution for your Cougar!

    This shot is of a used service replacement actuator. They are not as good as the originals and can be identified by the manner in which the upper seal is crimped in place. We will take this as a core from you in exchange for a remanufactured unit but we will not be sending you this version back as they are inferior in several areas. If you are wanting to sell us used cores we can not give as much for this version as we only use them to glean parts from.

    Replaces Cougar part number C9WY-13A167-A.

    *NOTE* Do not attempt to force "rock hard" old used hoses on the nipples. You will void the warranty. When installing good used hoses or our new hose kits you will want to apply a small amount of white lithium grease before installing the hoses on to the nipples.

    Do you want to replace those worn out actuators yourself or are you looking for some great information on your Cat’s headlight vacuum system? The video below is your ticket!


    Specifications:
    Weight: 2.00 LBS (weight shown may be the dimensional weight)
    (5.00 out of 5 stars) Customer Rating based upon 2 Review(s).
    Wilmington, DE

    Looks great, works great

    Material:
    Fit:
    Craftsmanship:
    Correctness:
    5.00 out of 5
    Pros:
    Cons:
    Well worth the investment, but of course there hasn't been enough time for me to judge the long term reliability of the remanufactured actuator. I did end up having to pull off the front license plate frame and lower valance to get the old one out and new one in (not too difficult--only a few bolts to remove and put back), but now I'm completely free of vacuum leaks in the headlight door system. Works well and visually indistinguishable from the original. Easier in my opinion than an electric conversion and of course more authentic to preserve the vacuum system.

    Nashville, TN.

    RE-BUILT 1969 HEADLIGHT VACUUM ACTUATOR

    Material:
    Fit:
    Craftsmanship:
    Correctness:
    5.00 out of 5
    Pros:
    • internal%20quality
    Cons:
    • small%20ding%20on%20case
    This item came to me in excellent condition. I sent in an excellent core from my 1969 Cougar convertible as well. Works fine and seems to have no leaks. Only time will tell if it lasts another 40 years but that is what I am planning on. Thank you Don for the hard work.

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