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On my recently acquired 1992 C4 the left headlight cover has some "play" in it. It opens and will close but has about 1/4 inch of play in the cover when closed. Is this due to the bushings in the gear being worn or breaking down that everyone seems to have to replace? The shaft on the motor does not seems to have any play it is almost if it is due to a bushing or something on the pivot side of the headlight. I do not mind pulling it all apart but if it is always the bushings I would like to have them on hand to make the repair while I have it apart.
St. Jude Donor '06-'07-'08-'09-'10-'11-'12-'13-'14-'15-'16
Could be that the cover is out of adjustment/loose. Run the light up manually until you can get at the bolts. Wiggle it around a bit and you should be able to see what needs to be tightened up:
Ok, pulled it apart and the problem is the pin that protrudes {or maybe it had two pin protruding) from the primary drive shaft has broken off. It was only the tension of the not pressing against the housing that was allowing it to work at all. The pin appears to have serrations within the drive shaft but not on the pin it self. Press out the old pin and do they have replacements? Whole new shaft? Or drill it out and replace with a pin appropriately sized?
It definitely had two pins protruding from the pivot arm at one time. Does not look like this part is available so drill out the old and replace with an appropriate sized pin that will fit both the hole and the slot for driving the housing.
Fixed! Indeed there were two pins in the pivot arm that had broken off. Surprisingly very harden pins that were in the pivot arm. I could not drive the old pin base out (not sure if it was fused in somehow. This pin was harder than tool steel and broke two bits drilling it out but successful in the end. Replaced with a 3/16 tension pin and after putting it all back together no more issues and working perfectly.
Could be that the cover is out of adjustment/loose. Run the light up manually until you can get at the bolts. Wiggle it around a bit and you should be able to see what needs to be tightened up:
Question. How is the top front attached (where the 2 tabs are)? Is it bonded on?
The bezel covering the light is held on by two screws in the front and two screws on the side that are only accessable after rotating the light open manually. With the bezel off there are 4 ten millimeter bolts holding the cover to the housing.
Headlight Cover Loose
