Help! Turn on lights and headlights pop up. Turn off lights and both doors go down, but the left side comes back up, have to use the manual screw on the motor to close. Turn the lights on and repeat the senario!! I replaced the GM gear in the motor with an Eckler's brass gear about two years ago, and it worked fine until a few weeks ago when this started. Has anyone seen this or have any ideas!!!!

 

Hey, did you copy a previous post of mine? Because I've had the EXACT same problem. I'm taking the passive-agressive approach, though. I'm pulling the pop ups in the spring and putting in fixed lights.

I also replaced the gears with brass gears, and I obviously didn't epoxy the covers back onto the headlight motors well enough because I finally noticed they were cracked open. I'm guessing by then the damage was done. I meant to do something about it, but before I had the time to get to it, the right head light started screwing up. It's sort of a shame since I had swapped out the crappy stock headlights and put in the European glass headlight assemblies with the high wattage bulbs and upgraded wiring harness. Not sure what I'll do with that stuff in the spring, but I'm fed up with pop ups for sure.

 

This is an easy fix. It involves putting 3 flat washers between the headlight motor and the frame, and replacing the plastic bumper gizmo that you will see is worn when you take the frame off. I was able to salvage the plastic bumper on mine by swapping the worn one with another one of them and flipping it over.

There is a GM technical update out that deals with this topic, perhaps someone will post it. BTW, this only occurs on the drivers side for some reason.

 

The following is a link to the info you need and the text from that link. The actual site has a diagram of the fix as well as the information below.

http://corvetteactioncenter.com/kb/q....php?qstId=217


2000: Service Bulletin: Left Headlamp Door Does Not Stay Closed
Number: 00-08-42-002
Subject: Left Headlamp Door Does Not Stay Closed (Shim Headlamp Door Motor/Actuator and Replace Insulators)
Model Year: 2000 Chevrolet Corvette

Condition

Some customers may comment that the left front headlamp door does not remain closed after the headlamps are turned off. Others may comment that the left headlamp door closes when the headlamps are turned off, but then reopens. In either case, the right headlamp door operates properly.

Correction

Important

The following information applies to the left front headlamp door motor/actuator only. It does not apply to and should not be performed on the right front headlamp door motor/actuator.





Install one washer (2) between the left headlamp door motor/actuator (1) and the mounting bracket (3) at each of the three attaching bolt locations. Also replace the insulator (4) on each of the two mounting bracket travel stop tabs (5) as shown. For information on headlamp motor/actuator removal, see the Headlamp Motor/Actuator Replacement procedure in the Lighting sub-section of Body & Accessories in the appropriate Service Manual.

Parts Information

Part Number
Description
Qty Per Vehicle

11505463
Washer
3

16524060
Insulator
2

 

THANKS, GUYS!!!! C-5 FORUM IS THE BEST!!!

 

Seems it's been awhile since anyone visited this issue on the forum.
My 2002 with 149,000 miles finally encountered the problem.
I reversed the two insulators (some call them bumpers) since they seem to have different wear characteristics.
I also ordered some from Eckler's even though I've been warned on the forums that they are pretty bad (brittle).
I don't really understand the deal with the washers in the Service Bulleting, but I added them anyway.
Here's a tip that might prove useful. When I told my Corvette mechanic that I was going to add the washers, he strongly suggested that I cut the washers so that I could slip them over the bolts without removing them. I did, and I can tell you that it saved me and my car a lot of headaches.
Headlights are working fine now. And, I'm glad because I head for Myrtle Beach next weekend.
Frank Hamilton

 

Here's the full TSB with the picture

Number: 00-08-42-002
Subject: Left Headlamp Door Does Not Stay Closed (Shim Headlamp Door Motor/Actuator and Replace Insulators)
Model Year: 2000 Chevrolet Corvette

Condition
Some customers may comment that the left front headlamp door does not remain closed after the headlamps are turned off. Others may comment
that the left headlamp door closes when the headlamps are turned off, but then reopens. In either case, the right headlamp door operates properly.

Correction
Important
The following information applies to the left front headlamp door motor/actuator only. It does not apply to and should not be performed on the right front headlamp door motor/actuator.



Install one washer (2) between the left headlamp door motor/actuator (1) and the mounting bracket (3) at each of the three attaching bolt locations. Also replace the
insulator (4) on each of the two mounting bracket travel stop tabs (5) as shown. For information on headlamp motor/actuator removal, see the Headlamp Motor/Actuator
Replacement procedure in the Lighting sub-section of Body & Accessories in the appropriate Service Manual.

Parts Information
Part Number Description Qty Per Vehicle
11505463 Washer 3
16524060 Insulator 2