89 headlight bushing replacement problem
Thread Starter
Pro
Joined: Jan 2004
Posts: 565
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From: Toronto ON
89 headlight bushing replacement problem
I'm trying to do this on the driver side without removing the headlight assembly or the motor. I've accessed the plastic gear and would have no problem if I could just get the thing to come out of the housing!
The plastic gear has on top of it an aluminum disk which looks nothing like the pics in Corvette Fever. How do I get the gear off the shaft? I don't know how forceful to be or the tools to use.
Thanks.
The plastic gear has on top of it an aluminum disk which looks nothing like the pics in Corvette Fever. How do I get the gear off the shaft? I don't know how forceful to be or the tools to use.
Thanks.
Le Mans Master
Joined: May 2005
Posts: 5,214
Likes: 65
From: Queensland, AUSTRALIA
I just did both of them on my 94, which are the same as yours. The easiest way is to remove the whole assembly from the hood, that way you will see what you need to remove screw wize. The aluminum disc you are refering to has a shaft going through the nylon gear, and is held in place on the other side by the rectangular piece of aluminum, there is a pin you need to push out of that in order to remove the disc, then the gear will fall out easily on the driver side. I personally DID NOT use new bushings, as this is only going fail again in time. I used steel shims to make a snug (not over tight or the gear will warp) and even fit between the gear and the drive disc. Either way you go, once you have that done, simply put it back together in the reverse order you pulled it apart. You dont need to remove the motor and from what ive heard i wouldnt recomend it either!!
Le Mans Master
Joined: May 2005
Posts: 5,214
Likes: 65
From: Queensland, AUSTRALIA
right hand side is a little more complicated due to the backwards installation of the gear and drive disc assembly. Youll know what i mean when youre in there, its not much different, just requires abit more jiggery pokery to get the gear in and out.
Thread Starter
Pro
Joined: Jan 2004
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From: Toronto ON
Is the "pic" you're talking about a type of pin, locaated between the headlight and the motor, actually holding the motor onto the whole assembly. I believe I can see that and can get to it.
I think this pin and the 3 torx screws actually hold the motor assembly onto the headlight assembly. I want to be on the right track.
I think this pin and the 3 torx screws actually hold the motor assembly onto the headlight assembly. I want to be on the right track.
Le Mans Master
Joined: May 2005
Posts: 5,214
Likes: 65
From: Queensland, AUSTRALIA
Originally Posted by Vett-eight-nine
Oh, btw, Case. From what I 've read, the bushings are the sacrificial pieces, this is why I'm inclined to replace with same (or nearly- I'm looking for a cheap fix). 
They are indeed sacrificial, how ever not needed in my opinion. The bushes cost money, and the steel shims with cost you next to nothing. You might have something lying around the house you can use and then its free!!!
Le Mans Master
Joined: May 2005
Posts: 5,214
Likes: 65
From: Queensland, AUSTRALIA
Originally Posted by Vett-eight-nine
Is the "pic" you're talking about a type of pin, locaated between the headlight and the motor, actually holding the motor onto the whole assembly. I believe I can see that and can get to it.
I think this pin and the 3 torx screws actually hold the motor assembly onto the headlight assembly. I want to be on the right track.
I think this pin and the 3 torx screws actually hold the motor assembly onto the headlight assembly. I want to be on the right track.
Burning Brakes
Joined: Aug 2005
Posts: 1,239
Likes: 0
From: North Central Indiana
I agree. It was much easier to remove the whole headlight and do it on a bench. Just put down a soft cloth to set it on so you don't scratch up the paint.
I removed the bracket that holds the connections for the headlight so I could remove the clips from the back. If you have a set of bent needle nose pliers it might be doable without taking the bracket off, but I didn't have a set and the bracket is only held on with 3 screws.
Once the headlight is out, I had to just loosen the torx screws on the bracket so I could move the motor the get to the bottom torx screw that holds the motor on.
I also used some grease to hold the shims in place when I put it back together.
I removed the bracket that holds the connections for the headlight so I could remove the clips from the back. If you have a set of bent needle nose pliers it might be doable without taking the bracket off, but I didn't have a set and the bracket is only held on with 3 screws.
Once the headlight is out, I had to just loosen the torx screws on the bracket so I could move the motor the get to the bottom torx screw that holds the motor on.
I also used some grease to hold the shims in place when I put it back together.
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Le Mans Master
Joined: May 2005
Posts: 5,214
Likes: 65
From: Queensland, AUSTRALIA
Originally Posted by Vett-eight-nine
Thanks for the replies, guys. I'm going to give it one more try with the headlight in place ( I just don't want to fool with the re-alignment) and then, I'll do it the right way. 
