H!. I have an interesting issue that I haven't seen an exact match to in the Corvette Forum. Maybe it's because my search/key words aren't well defined... Anyway... When I bought my 1993 convertible last summer, the passenger side motor was making the common gear striping noises, but were working properly. I figured I'd tackle it in the winter time which I just did. I took the headlight assembly off of the car. I had pre-ordered gears and the round cylindrical nylon bushings (3/ headlight assembly). The drivers side is very straightforward, and I didn't have to take the motor apart to get the large gear out. But the passenger side does need to come part. Oddly, the left and right assemblies are of differ designs. Why? I don't know, but they are! I believe in retrospect that if screws that hold the motor assembly are just loosened a bit, the gear has enough room to slip out, but I didn't know that then. I took the complete motor apart because one of the YouTubers did it that way. I cleaned the gear and removed the dust made by the 3 cylinders that decomposed over time (yeah, all C4 and C5 headlight assemblies will have this issue - 100s of thousands of headlight assembles!) and replaced everything and lubed the gear and the new cylindrical barrels/bushings, and then reassembled everything back together. So far so good... But I spoke too early because when I power on the lights, the driver's side turned on and rotated, but the passenger side light only powered on, but didn't rotate. When I powered off the lights, the drivers side rotated back and the lights powered off (normal); meanwhile the passenger side lights powered off, BUT the light assembly rotated to the UP position! So now the lights were out of sync or phase, whatever you'd like to call it. One down and one up. I tried many ideas to get them back to sync up, power and rotation. I tried turning the adjusters about 100 rotations and manually flipping the passenger side back closed and trying again. It did the same thing. I tried rotating the drivers side the same way, with the same result. I tried unplugging the lights until they were "synced up" and replugging the Passenger side, but the same problem happens during the cycle. It's very puzzling... But maybe...

I think I saw a post on the C5 forum that switching the green and grey wires on the 5 pin headlight assembly connector gets the motor back in sync if the magnets in the motor were reversed. Is this correct? It seems the C5 headlights can have a similar issue. And it might go back to when I reassembled the passenger side motor that I possibly reversed the magnets on the motor by accident. They are located 180 degrees across from each other. Personally, when I took the motor apart, it's impossible to tell which magnet goes on which side of the motor. It's not like they are color coded, or have a identifying markings. AND I don't know that if I open the motor again, whether I'll be able to catch the magnets in the position I had positioned them when I rebuilt the gear assembly, so that I can confidently reverse them and know it will work. I think my best option is to try the contact reversal method at the 5 pin connector. Currently the Green wire is on the outside and the Gray wire is inside of the Green wire on the "5 wire in a row connector" that feeds the headlight assembly. But a question might be, how to release the contacts from the connector housing and re-insert them in opposite order, meaning Gray wire outside, and Green wire to the inside? Does anybody have any suggestions? Hey, I suppose I should be thankful. The typical cylindrical nylon bushing replacement maintenance went well, and the motor now works and rotates smoothly and without noise! Now I just need to get them in sync!

Your thoughts and advise are most welcome. Thanks in advance guys! Jim