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95 Corvette, RH headlight won't rotate to closed position. Motor doesn't spin. Light won't shut manually. Would that indicate plastic bushing issue or motor failure? Light still works. Does that rule out motor being unplugged? Do I just need to spring for the very expensive replacement motor?
Can you hear the motor running, even though the headlight door no longer revolves?
Does the motor make a thumping noise when the motor limit switches are contacted? Sounds like thunka-thunka-thunka-thunk four to six seconds in duration.
These are classic symptoms of failed Delrin bushings.
Also, try swapping motor connectors on the headlight control module.
If the motor works after you've done that, there's a good chance it's your headlight control module. It's located on the driver's side fender well.
If you don't already have them, you might want to consider plastic headlights. They were stock on the 95 and are much lighter than the glass ones. Two plastic units appear to weigh less than one glass unit. I replaced my glass ones with the plastic units and they open much faster so I'm assuming this means a lot less strain on the motor/mechanism. The light output is good and appears the same as the glass.
I also have a 95 but the when I got it I didn't know they came stock with plastic as the previous owner had replaced them with the standard glass ones. Someone on the forum mentioned that 95s had plastic headlights and so I decided to check it out. The plastic ones aren't easy to find unless you know where to look. They were/are made by Wagner and the bar code number is 427223 56054 .
Model : Plastic Halogen HP6054 They are available thru NAPA autoparts.
Even though most of the NAPA stores carry the plastic units, I had a hard time discovering them as the store computer defaults to the glass units so use the info above to find them. They're about $22.00 each