Well as mentioned in my blower relay/circuit breaker post I am getting my 1966 Toronado back on the road FINALLY after she's had a long nap due to the transmission losing reverse and third gear about 24 years ago. Since then I did drive it a few times over the years locally and I do start it and run all the accessories several times a year as well as oil changes, adding fresh gas etc. so it wasn't DEAD for 24 years. Anyway I rebuilt a headlight actuator years ago and finally installed it. Another issue I had along with the right headlight not popping open was that the headlights switch was VERY hard to pull out to turn on the headlights. I've been down this road before and know how to take it apart and clean it all up etc. Anyway I had a "good used" one in my spare parts bin that moved freely so I decided to just install that one.

Upon installing it no matter what way I put the three vac lines on I could NOT get the headlights to work properly!! After getting frustrated and spending way too much time I compared my original switch to the "good used one" It turns out that someone must have taken it apart and when they put the top part of the vacuum portion on the switch they installed it 180 degrees from where it should be! The hoses/lines ports should face the firewall NOT the back of the cluster. Ok so I gently separated the port part from housing and flipped it around and tested it again in the car. With all lines to color coded ports once again I could NOT get the headlights to function right. I could get them to OPEN but not close, or just drop till locks keep them partly open OR even do nothing! I then took vac portion apart agaIn, and went out to the car and studied it and with me holding that black rubber "block" with L shaped channel in it I was able to slide the block back and forth and eventually get the lights to pop open and close properly I then CAREFULLY keep everything oriented as it worked and put the vac part of switch back together and once again tried it. AT the point of almost pulling my hair out after all this it STILL didn't work right!!!!!!

I figured out that from the FACTORY the color of the ports are mislabeled! I have THREE switches and they are all like this They have the GREEN port (Headlight UP circuit) where the VAC line (yellow) should be and Vice versa! I thought MAYBE just MAYBE its not marked right???? and I was indeed correct! once I swapped the green hose where yellow was it all worked correctly!!!! So for anyone doing this job it's NOT YOU!!! It's whoever made that switch (Trico ???) RED port is correct and above that should be marked Yellow and be vac supply The Port that has nothing below it should be GREEN that is for headlight UP circuit. The headlights will NOT function properly if you install your hoses in the color coded way. I've since scraped off the green. and yellow dots and re-did them with Testor's model paint. Almost a dead match LOL So that the next care taker doesn't lose his mind if he/she has to swap out or fix the switch. AND YES I even checked to make sure the hoses that pass through the fire wall weren't accidentally switch from green to vacuum instead of Yellow for vac. My yellow strip had Vacuum. Live and learn! What should have been a 1/2 hour to hr job turned into several hours and a good amount of frustration!! Hope this helps someone with a 1966 as this is a ONE YEAR ONLY switch and Toronado ONLY