lazy headlights
Thread Starter
Intermediate
Joined: Aug 2002
Posts: 32
Likes: 0
From: Princeton N.J.
lazy headlights
Why is it that sometimes one or both of my headlights fail to raise all the way up when I turn them on? It may take several attempts, and other times you wouldn,t know there was even a problem. Also, when I turn my headlights off the headlight motors seem to run on for several seconds even though the lights are all the way down. It,s a 1990 coupe. Thanks
Burning Brakes
Joined: Oct 2004
Posts: 1,094
Likes: 0
From: West Palm Beach Florida
You may have same problem I had.
The bushings are prob good and the shaft is stripped.
If you are handy I can walk you through a repair attempt, I did a Tech Tip on another Corvette web-site and I would be happy to copy and paste it here for you.
The bushings are prob good and the shaft is stripped.
If you are handy I can walk you through a repair attempt, I did a Tech Tip on another Corvette web-site and I would be happy to copy and paste it here for you.
Burning Brakes
Joined: Oct 2004
Posts: 1,094
Likes: 0
From: West Palm Beach Florida
Sorry I don't have any pics of this repair but the description is pretty good.
Tech Tip
What to check and repair if your headlight bushings are good and your headlight motor works but doesn't flip up.
Tools you will need:
1) 10mm socket
2) Ratchet
3) 3" or so ratchet extension
4) Dental pick set
5) Small E-clip pliers
6) T-27 torx socket
7) Bench vise
8 ) 7mm socket
9) Punch and hammer
10) Drill and drill bit set
11) Something to use as a pin (I recommend a small finish nail like for paneling)
12) Dremell type machine
13) Grease
14) Channel Lock pliers or similar pliers
15) Possibly new plastic bushings (found at Ecklers or other Corvette parts house)
Getting started:
1) Remove the headlight motor connector
2) Remove the 6 (10 mm) bolts holding the assembly to the hood
3) Remove the small E- clip on the motor shaft connecting it to the headlight linkage.
4) Remove the T-27 upper torx bolt on the headlight motor
5) Loosen the T-27 lower torx bolt
6) Remove the 3 t-27 torx bolts on the side of the motor
7) Remove motor and lay to the side removing the 3 (7mm) bolts holding the motor cover on
8 ) Using a dental pick set remove the large plastic gear gently by lifting upwards
9) You will find 3 plastic bushings under the gear
10) Inspect the bushings and replace as necessary
If the bushings look ok then you will need to look deeper. There is an aluminum (or pop metal) plate under the bushings that the bushings sit on. In the center of the plate there is a steel shaft that is splined to fit into the plate. This splined shaft my have stripped inside the plate. You can determine this by locking the plate into a vise (becareful not to mar the plate) then use a pair of channel lock pliers to try to turn the shaft (becareful not to mar the shaft). If the shaft has any play at all the shaft is stripped inside the plate and will need to be pinned in place to fix.
Using a vise, secure the aluminum plate and make sure the shaft is exactly where it needs to be (you will see wear marks on the shaft as to where it needs to be located).
Use a drill bit a hair smaller than your pin and drill straight through the aluminum plate and the shaft. Locate an area inside one of the indents where the bushings seat to drill the plate. (keep your drill bit cool with WD-40).
Then remove the shaft and enlarge the hole in the shaft to the same size as your pin.
The purpose of the 2 different size holes is so the pin will fit the shaft perfectly but have a pressed fit into the aluminum plate.
Press in the new pin using a brass punch and a small hammer.
Once the pin has been seated correctly and fully you will need to cut the pin and polish the edges where the pin is. Use your dremel tool to acomplish this.
Failure to clean and polish the edges will result in the bushings binding and premature failure of the bushings.
After the pin has been set and polished you will need to use some sort of grease to keep the bushings in place for reassembly.
Be sure to clean and lightly grease the bushings and gear using lithium grease, axle grease or anti-sieze grease.
Reverse the steps above to reassemble the motor and reinstall the headlight assembly.
When completed you may need to retention the electric motor. You can determine this by matching the speed to the opposite motor.
To adjust the tension you will need to loosen the large nut under the motor assembly and turn the flat head screw in or out and tighten the nut back up.
Tech Tip
What to check and repair if your headlight bushings are good and your headlight motor works but doesn't flip up.
Tools you will need:
1) 10mm socket
2) Ratchet
3) 3" or so ratchet extension
4) Dental pick set
5) Small E-clip pliers
6) T-27 torx socket
7) Bench vise
8 ) 7mm socket
9) Punch and hammer
10) Drill and drill bit set
11) Something to use as a pin (I recommend a small finish nail like for paneling)
12) Dremell type machine
13) Grease
14) Channel Lock pliers or similar pliers
15) Possibly new plastic bushings (found at Ecklers or other Corvette parts house)
Getting started:
1) Remove the headlight motor connector
2) Remove the 6 (10 mm) bolts holding the assembly to the hood
3) Remove the small E- clip on the motor shaft connecting it to the headlight linkage.
4) Remove the T-27 upper torx bolt on the headlight motor
5) Loosen the T-27 lower torx bolt
6) Remove the 3 t-27 torx bolts on the side of the motor
7) Remove motor and lay to the side removing the 3 (7mm) bolts holding the motor cover on
8 ) Using a dental pick set remove the large plastic gear gently by lifting upwards
9) You will find 3 plastic bushings under the gear
10) Inspect the bushings and replace as necessary
If the bushings look ok then you will need to look deeper. There is an aluminum (or pop metal) plate under the bushings that the bushings sit on. In the center of the plate there is a steel shaft that is splined to fit into the plate. This splined shaft my have stripped inside the plate. You can determine this by locking the plate into a vise (becareful not to mar the plate) then use a pair of channel lock pliers to try to turn the shaft (becareful not to mar the shaft). If the shaft has any play at all the shaft is stripped inside the plate and will need to be pinned in place to fix.
Using a vise, secure the aluminum plate and make sure the shaft is exactly where it needs to be (you will see wear marks on the shaft as to where it needs to be located).
Use a drill bit a hair smaller than your pin and drill straight through the aluminum plate and the shaft. Locate an area inside one of the indents where the bushings seat to drill the plate. (keep your drill bit cool with WD-40).
Then remove the shaft and enlarge the hole in the shaft to the same size as your pin.
The purpose of the 2 different size holes is so the pin will fit the shaft perfectly but have a pressed fit into the aluminum plate.
Press in the new pin using a brass punch and a small hammer.
Once the pin has been seated correctly and fully you will need to cut the pin and polish the edges where the pin is. Use your dremel tool to acomplish this.
Failure to clean and polish the edges will result in the bushings binding and premature failure of the bushings.
After the pin has been set and polished you will need to use some sort of grease to keep the bushings in place for reassembly.
Be sure to clean and lightly grease the bushings and gear using lithium grease, axle grease or anti-sieze grease.
Reverse the steps above to reassemble the motor and reinstall the headlight assembly.
When completed you may need to retention the electric motor. You can determine this by matching the speed to the opposite motor.
To adjust the tension you will need to loosen the large nut under the motor assembly and turn the flat head screw in or out and tighten the nut back up.
