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My 1994 'Vette has had a plethora of headlight problems. Mostly just aesthetic issues but lately my driver's side light will either come up half way, or not at all. I have replaced the gear and bushings within the motor but the same problems still arise. We have ruled out all possible electrical Gremlins. Anyone else with this issue? How did you fix it?
Have you tried running it through it’s rotation by hand using the **** on top of the motor? While doing that look and feel for any obstructions or rough spots in its travel. If it’s hitting anything or encountering too much resistance at any point during its travel that could be causing the trouble.