braveheart3158

I am in the middle of replacing the nylon bushings and gears on the passenger side headlight. I watched WILLCOX video and another one on youtube. Those video's are done on the drivers side. After removing the motor from the headlight and removing the three 1/4" screws I am looking at the gear but not able to push it our from the back or even pull it out from the housing. The back of the housing is sealed. Any help would be appreciated.

I have tried pulling on the shaft with channel locks and also the nylon gear.

I have 2 picture but do not remember how to post them here.

Firewalker11

on my 94 the back was held on by 3 screws which had to be removed. This isn't something you can do without removing the motor from its mount. I didn't get much from the Wilcox video, there is a better video with step by step directions online somewhere. I simply did a google search for replacing c4 headlight bushings and found the video.

It looks a lot worse than it is. The driver's side took me about 40 minutes, the passenger side only took about 10.

Hooked on Vettes

I believe your problem is because of the way the teeth are cut in the large
plastic gear and the way it meshes with the motor drive worm gear.

Loosen the 3 bolts that hold the motor housings together. Do not remove
the bolts completely or the case halfs will seperate and you will have
to reset the motor brushes.

Then pull the motor housings apart as far as the loosened bolts will allow.
They will seperate far enough so you get slack between the motors worm drive gear and the teeth of the large plastic gear.

Sometimes the bolt head will snap off and you may have to drill the rest of
the broken bolt out and use a small nut and bolt to replace it.

Sleazy Rider

go to this thread and to the link on post #7. i used it last night.

http://forums.corvetteforum.com/c4-g...y-up-down.html

tpfarm

Had the same problem with my 91. wriggled it and stared at it for a while and it finally came out. The worm gear meshes with the plastic gear tight but should come out with patience.

braveheart3158

Thanks. Done...never mind. Grabbed the shaft with the channels and had to pull xtra hard.

braveheart3158

Saw this. Thanks

braveheart3158

This was the solution. The video's show the shaft and gear being pushed out from the back. Was not possible with mine. Funny as soon as I got the new gear and the headlight reinstalled, the drivers side is making noise.

I would add that the 3 bearings inside the gear were completely gone. The threads on the gear were still good.. I suspect that the 3 bearings go first and leave all the nylon particles inside the gear threads. Thereby damaging the gear over time. Maybe that's why it may not be a good idea to use the brass gears with the plastic bearings.

braveheart3158

What is the relation of the two corvette forum sites? One is corvette forum and the other is corvette forumS.

LT4 F45

Every time i opened a C4 headlight motor those 3 bearings were shot and the gear in pretty good shape...

speedycat3

yep, most of the time the gears can be re used.