Thanks to everyone on the forum for the great assist on fixing up my first Vette, an '88 35th Anniversary that I love. I read all the links on replacing the headlight bushings and have torn into the passenger side but I cannot get the gear out for love or money.

I have removed the motor cover of course, loosened the 2 motor screws, loosened the big set screw by 2 turns but the white gear moves a little bit but seems to be hung up on something and won't come out of the housing. I inserted the punch thru the shaft hole to assist and yanked on it pretty hard I thought but it will not budge.

Any suggestions and thanks as always

Bob

 

Do not remove the screws that keep the motor housing to the gearbox. While the motor can be reassembled, it isn’t a fun job and should be avoided at all costs.

By placing a small screwdriver in the hole where the cotter pin resided, you can pull up on the gear assembly and remove it from the housing. It will be tight because of the worm gear, but it will come out.

Typically, you'll see powder when you separate the plastic gear and the metal shaft. That's because the nylon bushings have all but disintegrated.

You’ll have to clean all of this powder off the gear and housing before you reassemble them with the new bushings.

Remember how hard it was to pull the gear out? Takes a file and cut a groove in the back of the gear so it will slide in place easily.

Just remember to mark on the other side where the grooves are so you can find them should you ever have reason to pull the gear again.

Put some grease on the gear for lubrication and install the gear with the grooves mating with the worm gear. Install the three screws that hold the cover plate over the gears, and you’re ready to install the motor back on the headlight assembly.

When you install the motor back onto the headlight assembly, make sure that the spacers are in the proper places and that the motor shaft aligns properly.

 

Thanks OneDef I appreciate the tips. After gaining so much knowledge from this community I will attempt here to give back something, although small.

I tackled the bushing replacement in my '88 after reading all the online articles. Couple of observations

Make sure you have a T30 torx bit that is long and thin. The one I had fit a 3/8 ratchet and was too big around to fit in the recess to loosen the mounting bracket. I ended up with a T30 screwdriver bit on the end of a 1/4" drive and 1/4" socket. Alignment is also tricky but rotate the headlight assembly to get the access.

I would suggest starting with the left light first. On my 88 the motors are different (mirrored?) in that the motor cover comes off on a different side of the gear than the right one. Getting the gear out of the right one was a real challenge due to gear design but on the left side it almost dropped out. Confidence builder I think or maybe I get frustrated easy when the gear didn't come out after some real muscle.

Take the whole headlight and frame out of the car it's 6 bolts, easy to reinstall and ALOT easier than removing the motor on the car. IMO. I was panicky about alignment with the hole in the hood when I reinstalled but even for my **** retentivness it was easy to get back right on centered and looking good from the front.

Normal stuff I guess to Wd40 all the bolts and nuts for ease of reassembly.

Don't overlook the triangular shaped spacer on the motor shaft next to the frame. It HAS To go back on in the same position. If you get it wrong the light will THUD THUD THUD trying to open. Trust me I know.

Don't worry if after reassembly on the bench that the light is half open. That will correct the first time you cycle the light on and off.

Hope this helps. I found a few minor differences in the online instructions and my particular car but overall I could not have done it without the excellent resources here.. Thank you to all the contributors day after day and year after year.

Like most first light took me 4 hours the second one took 45 minutes! I can drive at night now!!

Bob

 

You should be proud, Bob. That headlight bushing replacement's a real-rite-of-passage moment in C4 ownership.