C4 Headlight Problem
Thread Starter
3rd Gear
Joined: Feb 2010
Posts: 3
Likes: 0
C4 Headlight Problem
I have a 96 CE LT4 coupe that I've owned since new, a daily driver until last January with over 100K miles. Recently the right headlight has started going up and down exactly 5 times before stopping in mid-cycle when the headlights are turned on. When cycling the motor is obviously torquing and binding somewhere, because it's wiggling back and forth despite being firmly attached. You can finish the cycle by turning the motor ****. Retraction is no problem. Following instructions found on this site I removed the headlight assembly with the thought of replacing the delrin bearings but after removing the motor from the headlight assembly I was unable to get the large nylon gear out of the housing. I did note that the gear casing was clean with no shards of plastic in the housing. I have checked everything, lubed everything, reinstalled the motor and it still happens. I know that there are pivot bushings involved in the assembly but since I don't know where they are supposed to be I obviously don't know if any are missing. Any ideas are welcome.
Melting Slicks
Joined: Aug 2008
Posts: 2,082
Likes: 50
From: Palmdale CA
I had a problem very Similar to your's, and it turned out to be the head light bezel was hitting the Coolant recovery tank, Aluminum pipe..when the hood was down, with the hood up the head light worked perfect.
I went ahead and replaced the Nylon gear, and bushings any how, and was surprised to find the old one's in good condition.
I went ahead and replaced the Nylon gear, and bushings any how, and was surprised to find the old one's in good condition.
Thread Starter
3rd Gear
Joined: Feb 2010
Posts: 3
Likes: 0
Headlight issue
It does it whether hood up or hood down. I have watched the entire mechanism working with the hood up, that's how I know that there is some kind of binding and that the motor torques and moves during operation. Thanks for the suggestion.
I still suspect that there are some bushings that have worn out and are missing. I just don't know what they look like and/or where they are supposed to go.
I still suspect that there are some bushings that have worn out and are missing. I just don't know what they look like and/or where they are supposed to go.
Advanced
Joined: Sep 2009
Posts: 75
Likes: 0
From: Newburgh In
C4 Headlight Problem
You might refer to the following: http://www.mamotorworks.com/PressReleas ... rticle.pdf
The article has some good pics in it. The bushings are under the big worm gear.
The article has some good pics in it. The bushings are under the big worm gear.
Thread Starter
3rd Gear
Joined: Feb 2010
Posts: 3
Likes: 0
Thanks for your reply and for the reference thread. I've checked those internal busings and they are OK. I suspect that there are bushings which are worn out and/or missing from the actual external linkage pivot points because there seems to be excessive 'play' in two locations on this linkage, one at the pivot point where the offset arm is attached to the actual motor and then one forward of that near the actual headlight pivot point.
Intermediate
Joined: Jul 2014
Posts: 34
Likes: 6
From: Virginia
THANK YOU! This just happened to me.. .right before VA inspection while I was in line. Looked up the symptoms on C4 Forum on my phone. This popped up... took 3 seconds to fix. Car passed.
I had a problem very Similar to your's, and it turned out to be the head light bezel was hitting the Coolant recovery tank, Aluminum pipe..when the hood was down, with the hood up the head light worked perfect.
I went ahead and replaced the Nylon gear, and bushings any how, and was surprised to find the old one's in good condition.
I went ahead and replaced the Nylon gear, and bushings any how, and was surprised to find the old one's in good condition.
Race Director
Joined: Mar 2015
Posts: 15,926
Likes: 579
Thanks for your reply and for the reference thread. I've checked those internal busings and they are OK. I suspect that there are bushings which are worn out and/or missing from the actual external linkage pivot points because there seems to be excessive 'play' in two locations on this linkage, one at the pivot point where the offset arm is attached to the actual motor and then one forward of that near the actual headlight pivot point.
If you did not get the gear off you did not see the ground up bushings. I drilled two spots in the gear shaft and used two oring picks to lever the gear off.
Last edited by antfarmer2; Jun 13, 2016 at 05:32 PM.
Race Director
Joined: Aug 2007
Posts: 11,889
Likes: 8
From: Whitefish Falls Ontario
St. Jude Donor '08-'09
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Drifting
Joined: Sep 2014
Posts: 1,579
Likes: 59
From: Trieste Italy
I have a 96 CE LT4 coupe that I've owned since new, a daily driver until last January with over 100K miles. Recently the right headlight has started going up and down exactly 5 times before stopping in mid-cycle when the headlights are turned on. When cycling the motor is obviously torquing and binding somewhere, because it's wiggling back and forth despite being firmly attached. You can finish the cycle by turning the motor ****. Retraction is no problem. Following instructions found on this site I removed the headlight assembly with the thought of replacing the delrin bearings but after removing the motor from the headlight assembly I was unable to get the large nylon gear out of the housing. I did note that the gear casing was clean with no shards of plastic in the housing. I have checked everything, lubed everything, reinstalled the motor and it still happens. I know that there are pivot bushings involved in the assembly but since I don't know where they are supposed to be I obviously don't know if any are missing. Any ideas are welcome.
Last edited by Christi@n; Jun 14, 2016 at 04:49 PM.
