So to start off I had purchased my C4 with the intentions of making it a project car and by god it is holding up its name as a project car. I have been having a headlight problem for weeks and I simply don't know what to do next. The problem is only happening with the Passenger side, but I have done maintenance on both just to be sure. I have replaces both gears in the motors with plastic ones, I know getting the copper gears is an option, but I don't have that sort of money for all 4 gears, I have replaces all 3 motor relays, and I have rebuild these motors more times than I am proud of, but every time I have the right headlight assembly closed it continues to want to close and makes the notorious thumping noise, but it doesn't stop after 5-10 seconds it keeps on going. I have read forum after forum and I haven't seen anyone with the same problem as me. To give a point of reference in timeline wise, when I first got the car It did have the headlight problem when I would open it it would make the thumping so I replaced the gears because they had been destroyed, it solved the problem for a few weeks or about 50 headlight activations, but the problem started again so then I thought I'd replace the relays after some research thinking that it may be a faulty one, but that didn't work. I have taken apart the problem motor to see if the new headlight gears that I put it decided not to work, but they don't have any sort of damage in both from skipping or grinding so now I'm here making this post hoping someone has an answer. At this point if I have to disassemble the headlight motor one more time imma cry.

I have researched into if I could simply replace the whole assembly but the 84'-87' headlight motors have been discontinued and ones that I have seen that independent sellers are selling are at least $200+, I have seen that corvettecentral has a headlight motor upgrade kit, but its $735 before shipping and I just don't have that money so I have done research, but im wanting to see if I need to bite the bullet and either buy the metal headlight gears, a refurbished headlight motor or the headlight motor upgrade kit.

 

i believe there little switches in the motors for up and down check them and make sure relays are correct

 

What do they look like. Are they an actual component inside motor itself and apart of the motor?

 

Let me look at making the wiring harness. I’ve got all the other parts for the conversion. Might be a good way to start getting rid of headlight parts.