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I tried to use the search function, but I must not be using the correct combo of words?
Anyway, what are your thoughts on swapping out the headlight motor gear to a brass gear? My driver's side is just starting to make noises after opening or closing and I am pretty sure that the gear will need replaced sooner rather than later. I have been looking at replacements and noticed that there is a brass option vs plastic. Looking for input on if it is worth the extra $$ to switch over?
Looking for input on if it is worth the extra $$ to switch over?
You didn't mention the year, but considering the newest C4 is now 21 years old and your plastic ones lasted this long...personally I don't see the benefits of brass.
My 88's originals lasted almost 25 years, then I replaced them with the plastic gears and had the motors rebuilt. Not sure how much better the brass would be, obviously the teeth are stronger. Its been about 4 years and no issues.
I would suggest using the plastic instead of the brass. If there is a problem you would rather strip the plastic gear and save the motor which runs in the $300 plus range than have the brass gear hold together and ruin the motor.
I would suggest using the plastic instead of the brass. If there is a problem you would rather strip the plastic gear and save the motor which runs in the $300 plus range than have the brass gear hold together and ruin the motor.
My problem with the plastic is this. When it breaks again, regardless of how long it has lasted to date, is there going to be another gear available? How many C4s are available today and how many will be there in say 10 years? Maybe the manufacturer sees the writing on the wall and decides to make one last run and you are a day late and a dollar short.
I believe the earlier C4's '84~'87 had more problems with the plastic gears wearing out and failing than the later '88~'96 C4's did. The earlier models had a 2 headlight drive gear system while the later models had one. The later model years were upgraded with smaller quieter motors. The related relays to operate the flip up headlights were reduced from three to one on the later models as well.
The metal or bronze gears were first made to fix worn out plastic gears for the earlier two gear C4's. Then the aftermarket began to make bronze replacement gears as an upgrade to the single OEM plastic gear in the later C4's although they're rarely required.
It's the three nylon bushings that virtually always fail (basically they turn to dust) and render your headlight inoperable for all C4 model years.
Mine had the bushings being bad but later on, I found hairline cracks on the plastic gear.
My OEM plastic gears were fine after 24 years of use ('89 C4) it was the three white bushings that were completely gone.
I replaced my OEM plastic headlight gears with aftermarket bronze parts (ordered before I took the headlight motors apart) but that was completely unnecessary as the OEM parts were fine.
So if anyone needs some OEM nylon headlight gears for a late model C4 ('88~'96) PM me.
My OEM plastic gears were fine after 24 years of use ('89 C4) it was the three white bushings that were completely gone.
I replaced my OEM plastic headlight gears with aftermarket bronze parts (ordered before I took the headlight motors apart) but that was completely unnecessary as the OEM parts were fine.
So if anyone needs some OEM nylon headlight gears for a late model C4 ('88~'96) PM me.
PM sent.
2 really nice used originals from a 93 for sale @ $25 to anyone else if you do not want them.
I would suggest using the plastic instead of the brass. If there is a problem you would rather strip the plastic gear and save the motor which runs in the $300 plus range than have the brass gear hold together and ruin the motor.
This. There's a reason it's the weakest link. It's to save the motor. Brass may "seem" like a good idea but to me replacing plastic gears is a better idea than replacing a motor.
This. There's a reason it's the weakest link. It's to save the motor. Brass may "seem" like a good idea but to me replacing plastic gears is a better idea than replacing a motor.
Are there many instances of motor stripping the gear?
Are there many instances of motor stripping the gear?
Stripping? The plastic wears out over 30 years.. I replaced mine last year, which actually is an impressive run. I don't expect the same results with the new plastic gears though since nothing these days seems to be of good quality. Especially with aftermarket car parts.
Stripping? The plastic wears out over 30 years.. I replaced mine last year, which actually is an impressive run. I don't expect the same results with the new plastic gears though since nothing these days seems to be of good quality. Especially with aftermarket car parts.
The thought was to make the gears the sacrificial unit. I thought the pellets were already the sacrificial items. So I'm curious how many people found their gears stripping and thus how big a problem it is. I'd be OK with replacing plastic gears other than the question of how much longer it is going to be available. That made me go bronze.
My problem with the plastic is this. When it breaks again, regardless of how long it has lasted to date, is there going to be another gear available? How many C4s are available today and how many will be there in say 10 years?
In 10 years, we'll be making these types of parts ourselves using 3-D printers.
Headlight gear replacement - brass or plastic
Yep that's the general consensus. 
