bushings are a major cause of headlight probs 
Flipping out over headlights...
Thread Starter
Racer
Joined: Aug 2004
Posts: 252
Likes: 0
From: Corpus Christi TX
Flipping out over headlights...
well, I'm not to that point yet, but it is an irritating problem. The headlights on my '89 Coupe are sort of arbitrary in when they want to work, and I'm not sure why.
Symptoms: Left side headlight starts out a split second late, but flips completely. Right side headlight gets stuck half way, bounces back and forth a few times, then goes the rest of the way. However, it doesn't stay put, rather it flops loosely. (I had to ziptie it in place and disconnect the motor the night I discovered this).
Now here is where it gets weird. I thought maybe a few teeth had been stripped off of the plastic gears in the headlight motor assembly, accounting for the bouncing and looseness, but when I gave the lights a quick test run before dismantling the assembly, they both worked fine. Then the problem came back the next day.
I don't know if this is an electrical problem, a mechanical problem, or just the gremlins messing with my head. If anyone has any thoughts, I'd sure like to hear them.
Symptoms: Left side headlight starts out a split second late, but flips completely. Right side headlight gets stuck half way, bounces back and forth a few times, then goes the rest of the way. However, it doesn't stay put, rather it flops loosely. (I had to ziptie it in place and disconnect the motor the night I discovered this).
Now here is where it gets weird. I thought maybe a few teeth had been stripped off of the plastic gears in the headlight motor assembly, accounting for the bouncing and looseness, but when I gave the lights a quick test run before dismantling the assembly, they both worked fine. Then the problem came back the next day.
I don't know if this is an electrical problem, a mechanical problem, or just the gremlins messing with my head. If anyone has any thoughts, I'd sure like to hear them.
Le Mans Master
Joined: Aug 2003
Posts: 9,884
Likes: 3
From: Magnolia Mississippi
St. Jude '03-'04-'05-'06-'07
Originally Posted by super89
well, I'm not to that point yet, but it is an irritating problem. The headlights on my '89 Coupe are sort of arbitrary in when they want to work, and I'm not sure why.
Symptoms: Left side headlight starts out a split second late, but flips completely. Right side headlight gets stuck half way, bounces back and forth a few times, then goes the rest of the way. However, it doesn't stay put, rather it flops loosely. (I had to ziptie it in place and disconnect the motor the night I discovered this).
Now here is where it gets weird. I thought maybe a few teeth had been stripped off of the plastic gears in the headlight motor assembly, accounting for the bouncing and looseness, but when I gave the lights a quick test run before dismantling the assembly, they both worked fine. Then the problem came back the next day.
I don't know if this is an electrical problem, a mechanical problem, or just the gremlins messing with my head. If anyone has any thoughts, I'd sure like to hear them.
Symptoms: Left side headlight starts out a split second late, but flips completely. Right side headlight gets stuck half way, bounces back and forth a few times, then goes the rest of the way. However, it doesn't stay put, rather it flops loosely. (I had to ziptie it in place and disconnect the motor the night I discovered this).
Now here is where it gets weird. I thought maybe a few teeth had been stripped off of the plastic gears in the headlight motor assembly, accounting for the bouncing and looseness, but when I gave the lights a quick test run before dismantling the assembly, they both worked fine. Then the problem came back the next day.
I don't know if this is an electrical problem, a mechanical problem, or just the gremlins messing with my head. If anyone has any thoughts, I'd sure like to hear them.
Racer
Joined: May 2005
Posts: 472
Likes: 1
From: looking for my insanity state of confusion
Sounds like the crappy bushings that disintegrate. My 92 does the same thing on the drivers side. There is a nice write up in the tech tips section on the replacement of bushings, and you save money by going to Home Depot for the parts. I just have to wait to get back in country to fix mine 
:
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Instructor
Joined: Apr 2005
Posts: 128
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Melting Slicks
Joined: Dec 2004
Posts: 2,471
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Bushings will turn into powder
My 1990 headlights did the same thing. The problem was intermittent, but it gradually got worse. Eventually I was caught in heavy rain without being able to use them.
Replace the bushings if you plan to do any driving at night or in the rain. Even the manual crank system won't work if the bushings or gears are in bad shape like mine were. I learned that the hard way.
I tried to replace the bushings, but I didn't have enough tools or know-how. So, I removed the headlight assembly and took them to a professional mechanic, and he gave me a discount because I had removed the headlights. He also installed metal gears that the previous owner had purchased and given to me. The new bushings and gears solved the problem. -- Eric
Replace the bushings if you plan to do any driving at night or in the rain. Even the manual crank system won't work if the bushings or gears are in bad shape like mine were. I learned that the hard way.
I tried to replace the bushings, but I didn't have enough tools or know-how. So, I removed the headlight assembly and took them to a professional mechanic, and he gave me a discount because I had removed the headlights. He also installed metal gears that the previous owner had purchased and given to me. The new bushings and gears solved the problem. -- Eric
Team Owner
Joined: Oct 2000
Posts: 96,443
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From: Fort Knox, KY
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It's your bushings!
Purchase them online at MAM's or Eckler's or Home Depot and use the TechTips section on this forum and this Corvette Fever article to get started.
http://corvettefever.com/howto/33098/
Purchase them online at MAM's or Eckler's or Home Depot and use the TechTips section on this forum and this Corvette Fever article to get started.
http://corvettefever.com/howto/33098/
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Burning Brakes
Joined: Nov 2005
Posts: 848
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From: 1992 LT1 6 speed Cayman Islands
It is the plastic bushings. The left one can be changed without removing the headlight from the car. Just punch out the rollpin in the shaft and the three bolts that hold the cover can be removed then the cover can come off. Put in the three new bushings and the left side is done.
Instructor
Joined: Jul 2004
Posts: 115
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From: Cicero, IN "Change is inevitable, except from vending machines"
I did my bushings myself using the tech tip from the forum. First one took me about 1.5 hr and second was 45 mins including removal & install. It's not hard, just follow the instructions. 
Team Owner
Joined: Oct 2000
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From: Fort Knox, KY
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Originally Posted by Leavundst
I have the same problem but on mine the bushings where ok and the gear was worn. The first one you do is a real pain. From there on it's actually fast and easy.
Safety Car
Joined: Nov 2001
Posts: 4,166
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From: Las Vegas NV
The replacement bushing are also available at your local parts store that sells "HELP" / "MOTORMITE" brand items.
They are the same for ford truck window regulators. About $6.00-$8.00 per side at the parts stores.
They are the same for ford truck window regulators. About $6.00-$8.00 per side at the parts stores.
Team Owner
Joined: Oct 2000
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From: Fort Knox, KY
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Originally Posted by DaBo
motormite parts # 74410
Team Owner
Joined: Feb 2006
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From: sw Ohio
If you have a '84-'87 vette, the headlight gears inside the motor need to be replaced. If you have the '88 and up style there is one gear and some delrin bushings that need to be replaced. Sounds like it could be both sides, definitely the right side though.
Team Owner
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From: Fort Knox, KY
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Originally Posted by 4Ever21
If you have a '84-'87 vette, the headlight gears inside the motor need to be replaced. If you have the '88 and up style there is one gear and some delrin bushings that need to be replaced. Sounds like it could be both sides, definitely the right side though.
Burning Brakes
Joined: Feb 2006
Posts: 1,098
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From: Webster Texas
motors
I had the same problem w/my '84. Picked up rebuilt motors from scarabexc@aol.com. Also bought a digi dash from him. If you choose not to rebuild your own motor contact him.
