onedef92

With so many members requesting headlight motor repair help, I thought I'd post this useful resource.

If you have a 1988 through 1996 C4 and accidentally damage one or both of your headlight motor BRUSHES during your repair attempt, don’t despair.

You can use Bosch item number 3604321509 (electric motor brushes) that will slide right into the O.E.M. mounts, but you'll have to file them down slightly using a piece of emery cloth.

You can get these from any electric tool repair shop. Locally, I purchased a set for $9.22 (tax included) at Tool Repair Service, Inc. 1200 Goss Ave., Louisville, KY 40217 502-635-6888.

To re-insert the commutator, I used a piece of safety wire to hold the brushes in place while I re-installed the commutator shaft. You can also use dental floss.

VR'92

You are the headlight master OD.

onedef92

Like my grandma used to say, "no one ever got any WORSE by practicing."

Still, I don't look forward to repairing mine again for a long time to come.

jfb

Where can I get some replacement contacts for the reversing/stop motor contacts?

onedef92

Try Alan Moody in Florida who used to make replacement gears out of brass which he sells for $50 each. (Phone number: 407-275-5040).

You can also contact Ecklers Corvette (mail order place out of Titusville, FL. Phone number: 1-800-327-4868)

bogus

wow Julian... you are da man!

So far, my headlights are just fine - knock on wood... or a suitable wood like substitute.

I will keep that info!

884fun

Thanks for posting this tip and part numbers. I'll be on vacation starting Friday and will be doing both of my motors with the bushing replacement. I'm going to pickup the brushes you listed and replace those while I'm already in there.

Thanks a lot for sharing your info with the rest of us.

onedef92

No problem. Unless you break a brush during a repair attempt, you shouldn't have to. The motor brushes seldom fail, and it's not advisable to open up the cylindrical-shaped motor housing they're seated inside anyway.

At least, you DO NOT have to open this part of the unit to replace the BUSHINGS, which are far more failure-prone. I just offered the parts number as a just in case, from personal experience.

bogus

You know, I wonder if these brushes would also work in the power window motors?

onedef92

I don't know. I've never serviced a Corvette power window motor.

But these guys MIGHT be able to get the window motor brushes for you.

http://dandmrestoration.home.mindspring.com/motors.htm

bogus

when the passenger motor goes south... I will check that out! thanks!

hypervdh

I know this is an old thread but I ran into this problem while trying to figure out how to fix the bushings myself and figured I'd join and update this for anyone who needs it. This forum has been a great place to get information for me.


Bosch has a new part number to replace the one in the OP. It is # BOS2604321514. Price was $8.46 per set. I filed them lightly with emery cloth and they dropped right in. I got them from a local power tool repair store.