So I took my car to the dealer today to have the headlight gap fixed, its about 1/2" on the drivers side, the front end is aligned terribly also...

6 hours later they give me my car back and there solution was to:
1. Make the front bumper loose as hell
2. Make the gap on the passenger side equal to the gap on the driver's side

Obviously this was not acceptible, I did not get mad, but I made sure my point was heard.
They followed the instructions in the service bulletin, but now thanks to me they are challenging GM to issue a new service bulletin or recommendation for a whole new bumper when this situation arises.

There is no possible way to get rid of the gap given the current dimensions of my front facia. If one were to raise the facia it would rub badly, and the headlights can not be adjusted further.

They are going to call the TAC tommorrow, and hopefully I will get a new front facia, anyone been involved with this fiasco?

Cheers,
Ryan

 

I find that this **** is as per dealer, I ve gone to one dealer only to get nothing resolved because they canot get it right, And then go to another dealer and fixed no problem....find another dealer

 

I have the same gapping issues on my lights. Dealer told me it was because the car was jacked up wrong, giving me my hood issue and messing up my bumper. I'm going to switch dealers because in 2 months i'll be working for one.

 

when I took my car in for that same problem the body shop guy said that he looked at it couldnt get to line up or fix the gap said the bumper was made to big for the car.
A week later I took him the post from here that hd the how to from GM and he read it and said he didnt think that would fix it either.

Keep up posted on what your dealer finds out.

 

i took mine to the dealer for the same thing, they looked at it and set me with an appointment to get them to take it off the car but i have a gap on the headlight, along the fenderwell isnt a smooth transfer

 

almost all cobalts have it........i just live with mine kinda

 

I had a bad gap on the passenger side - some of the AZ folks will vouch for that - I could fit my fingers between the headlight and the bumper. I had to actually show the TSB about it to my dealer, but once I did they were very grateful for the help, and they fixed it perfectly. I don't have pics of the gap, but I'll post some up later of what it looks like now.

 

yea, I painted my headlights, and when i went to re-install them, i noticed I had gaps....now i gotta work on it.

 

that what iv found as well it depends on the dealer you go too

 

I also have the same problem. It wasnt bad until I removed the headlights to paint them and not there is a noticably bigger gap on the driver side than on the passanger side

 

i know, and im soo lazy, and I have no ambition left for this week at all, so i keep putting it off

 

If anyone gets some semi easy instructions on fixing this - please post here.

I have a bit of a "bulge" gap now under the driver side headlight after putting in my dual halo projector headlights. I am pretty sure they have the same dimensions as the original lights. A few hits from the palm of my hand seemed to re-centre the bumper - but still the gap in that one spot.

 

i said screw it iam getting a new bumper anyways so oh well off with the stock

 

i cant find the tsb about this can someone point me in the right direction please

 

My dealer spent 4 hours on it and enven took the bumper off and it still looks like crap.
The bumper dosnt fit right under the headlights and the drivers side where the bumper meets the hood has a gap so big I can get my fingers in there.

good luck man. Im going to have to take the car apart my self to fix it the right way looks like.

Later

 

I own a 06' LT that had a large gap on the left side of the headlight. My drivers side headlight was installed incorrectly at the factory. Look under your hood where the headlight is bolted in... The grey plastic headlight is attached to a black piece of plastic which is bolted into the metal quarter-panel. On my car the headlight was connected correctly to the black piece of plastic, but the black piece of plastic was bolted into the wrong hole in the quarter-panel. Basically my drivers side headlight was pointed directly into oncoming traffic. I figured it out by comparing where the left side headlight was correctly bolted in, compared to the right side which was not. There is an oval-like hole in the quarter-panel directly behind where the headlight is susposed to be bolted in. My light had been bolted further back into that oval hole. Once I got it bolted correctly, the gap dissapeared.

Damn'd GM robots! or, maybe Slim Shady installed it at the factory?

 

well i had a slight gap but my new projectors seemed to fill that all in so it looks better

 

MY dealer Fixed Mine >>>>No Problem!
Is A simple Light adjustment!

 

Ok, dealer fixed mine, took them 12.5 hours, I refused to accept their first "fix", make sure you are solid on your stance until the gap is acceptable! The bumper was adjusted until it fit nearly perfectly. At first it didn't look like there was a hope in hell it would fit, but after taking it back the second time and spending 6 more hours they got it. Tech explained that they had to increase the hole on the passenger side 5mm in order to properly line-up the facia.

Ryan

 

Do the 2007s have this problem?

 

I thought the purpose gap under the drivers side lamp was to feed air to the stock airbox.

 

I have a large gap on one headlight also...but i havent taken my car back in. I have a long list of items..

 

well here it is.
through my own experimentation i found the solution.

what you have to do is remove the headlight.
there are two screws on top then remove the wiring harness

you will then see a black plastic platform that hold the headlight in place.
there are two screws in front very low then i think one or two at the top.
after removing the black plastic housing you will see the frame of the car.
remember those two screws that you removed from the front you will see a braket that is attached to the frame.
one screw holds that braket in and then the braket will slide back and forth.

move the braket forward a small amount and with a little trial and error you can remove the gap.

hope this helps everybody.

 

I'm gonna give that a shot tonite when I get home. thanks bro

 

I'm pretty sure the "bulge" gap under the middle of my light is from the fender position.

Looks like a matter of moving that body panel back a bit.
The gap at back of fender (at pillar, door) should match passenger side after (it is a tiny bit larger atm).