Headlamp motor issue/question.
Thread Starter
Pro
Joined: Mar 2005
Posts: 566
Likes: 0
From: Shelton, Connecticut
Headlamp motor issue/question.
I went to turn on my headlamps last night and the driver's side would not pop up. I turned them on and off a few times with no luck. So I popped the hood and played with the *** and tried again and it went up. Then when I shut the lights off I got a clicking sound when the lamp door would close for a few seconds. After a few "up and downs" the headlamp would not come up again. So I turned the *** again(counterclockwise) to get it to come up. Problem is, if I turn it too far the the door won't close, if I don't go far enough I get that clicking sound and then lose operation again. Is there a "sweet spot" I need to find on this adjustment or do I need a new motor>??? Thanks for any tips or help. -Mat- 
Tech Contributor
Joined: Dec 2003
Posts: 19,384
Likes: 87
From: Horncastle Lincolnshire, England
2023 C5 of the Year Finalist - Unmodified
Sounds like you have a stripped headlamp motor gear. Its fairly common. The symptoms are a loud clicking which runs on after the door has closed. The plastic gears get damaged and the teeth don't engage. When you're moving the gear manually you're aligning a part of the gear that either has teeth or doesn't hence the erratic operation.
You can have the dealer change the motor or do a DIY change. plenty of threads on how to if you do a search.
Probably a better option is many of us have bought the DIY kit to fit brass gears:
http://www.rodneydickman.com/retail_new.html
Look in the electrical section for 97-04 Corvette Headlight brass gear kit. It comes with fitting instructions.
You can have the dealer change the motor or do a DIY change. plenty of threads on how to if you do a search.
Probably a better option is many of us have bought the DIY kit to fit brass gears:
http://www.rodneydickman.com/retail_new.html
Look in the electrical section for 97-04 Corvette Headlight brass gear kit. It comes with fitting instructions.
Last edited by DeeGee; May 22, 2006 at 09:15 AM.
Thread Starter
Pro
Joined: Mar 2005
Posts: 566
Likes: 0
From: Shelton, Connecticut
Originally Posted by DeeGee
Sounds like you have a stripped headlamp motor gear. Its fairly common. The symptoms are a loud clicking which runs on after the door has closed. The plastic gears get damaged and the teeth don't engage. When you're moving the gear manually you're aligning a part of the gear that either has teeth or doesn't hence the erratic operation.
You can have the dealer change the motor or do a DIY change. plenty of threads on how to if you do a search.
Probably a better option is many of us have bought the DIY kit to fit brass gears:
http://www.rodneydickman.com/retail_new.html
Look in the electrical section for 97-04 Corvette Headlight brass gear kit. It comes with fitting instructions.
You can have the dealer change the motor or do a DIY change. plenty of threads on how to if you do a search.
Probably a better option is many of us have bought the DIY kit to fit brass gears:
http://www.rodneydickman.com/retail_new.html
Look in the electrical section for 97-04 Corvette Headlight brass gear kit. It comes with fitting instructions.
I am not sure that is the issue though. Anyone have any other insight on this>??? -Mat-
Racer
Joined: Aug 2003
Posts: 314
Likes: 0
From: Houston TX
Originally Posted by SVT F15O
Thanks, I ordered the kit.
I am not sure that is the issue though. Anyone have any other insight on this>??? -Mat-
I am not sure that is the issue though. Anyone have any other insight on this>??? -Mat-
Melting Slicks
Joined: Nov 2001
Posts: 3,088
Likes: 1
From: NC
Originally Posted by fovsky
Here's an insight: stop messing with it until the kit arrives. After mine started acting erratically I opening and closed it over and over to try and diagnose the problem and I ended up stripped my gears so badly I couldn't manually raise the headlight anymore. Guess what step one is in the directions of the kit? Yep, raise the headlight. When I finally figured out how to get in there the gear was shredded...not just the teeth but the entire gear. Good luck with the fix. I'm sure Rodney's gear will remedy your problem.
Raise the headlights and remove the motor fuses until you get the kit.
The fuse box is in front of the battery and the fuses are 10 AMP # 3 & 4
...George
Le Mans Master
Joined: May 2003
Posts: 5,362
Likes: 3
From: Delray Beach FL
Just did mine last weekend. Tools needed: 13mm socket and wrench ,10mm socket and wrench, screwdriver, large hammer, and some shoe glue or similar adhesive.
You have to remove the whole headlight assembly (not too bad..3 - 13mm bolts & 5 or 6 nuts depending on driver or passenger side. Pass side has the headlight module mounted there as well). Then, remove the motor from the assembly. All of that is easy. Hard part I had was getting the motor case to separate to get the old gear out and put the new one in. Ended up using a screwdriver and hammer to knock the cover off. Then, pull the gear out, grease up the new one a little, use some silicone adhesive to close it back up and reinstall. Took me 1 1/2 hours to do it...tried at first to remove the motor from the assembly with the assembly still on the car. That doesn't work...unless you take off the hood and the hinges. Then you could get it off.
If the other side goes out, should take around 30 minutes to swap out the gears.
BTW...mine was under warranty, but I didn't have the time to have it sit at the dealer for a week to replace this gear. Did it myself to keep the dealer from breaking something else in my Z.
You have to remove the whole headlight assembly (not too bad..3 - 13mm bolts & 5 or 6 nuts depending on driver or passenger side. Pass side has the headlight module mounted there as well). Then, remove the motor from the assembly. All of that is easy. Hard part I had was getting the motor case to separate to get the old gear out and put the new one in. Ended up using a screwdriver and hammer to knock the cover off. Then, pull the gear out, grease up the new one a little, use some silicone adhesive to close it back up and reinstall. Took me 1 1/2 hours to do it...tried at first to remove the motor from the assembly with the assembly still on the car. That doesn't work...unless you take off the hood and the hinges. Then you could get it off.
If the other side goes out, should take around 30 minutes to swap out the gears.BTW...mine was under warranty, but I didn't have the time to have it sit at the dealer for a week to replace this gear. Did it myself to keep the dealer from breaking something else in my Z.
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