Dreaded Headlight Issue
Thread Starter
Melting Slicks
Joined: Jun 2003
Posts: 2,767
Likes: 0
From: Indianapolis IN
Dreaded Headlight Issue
The Wifey and I went to dinner tonight. As I was pulling in, I dropped my headlights on my 01 coupe. The drivers side headlight motor started grinding like crazy after it went down. It carries on for about 5 seconds and then stops. The lights still go up and down, but everytime they go down, the driver's side makes that horrible noise.
I've done lots of forum reading on the problem tonight. I have a couple of questions.
Does this sound like a problem with the gears or the entire motor?
Would it be easier to just replace the entire motor instead of fumbling with the little gears? I see Ecklers has the motor for $129. That's not bad if it's going to save me a bunch of hassle.
Is this indeed an easy job? Some people are swearing it can be done in under an hour, some are saying it's a pretty hard deal.
Are there any step by step instructions around here (maybe with pics)?
Thanks to all of you gurus for the help!
I've done lots of forum reading on the problem tonight. I have a couple of questions.
Does this sound like a problem with the gears or the entire motor?
Would it be easier to just replace the entire motor instead of fumbling with the little gears? I see Ecklers has the motor for $129. That's not bad if it's going to save me a bunch of hassle.
Is this indeed an easy job? Some people are swearing it can be done in under an hour, some are saying it's a pretty hard deal.
Are there any step by step instructions around here (maybe with pics)?
Thanks to all of you gurus for the help!
Night Owl for life
Joined: Nov 2003
Posts: 24,719
Likes: 4,556
From: Bugs Bunny should'a made a left turn here
it's the gear.
replacing the whole motor is easier than replacing just the gear but the gear will fail again eventually.
the gear swap is not too difficult and there are many walkthroughs here on the forum.
you can also see the walkthroughs from Brent Franker:
http://www.bfranker.badz28.com/headlightfix/index.htm
or Rodney Dickman:
http://www.rodneydickman.com/n113.html
Of the 2 styles available, i'd go with the solid Bfranker ones because the rubber bushings have failed again on me with my Rodney kit.
The Franker kit doesn't have those issues.
replacing the whole motor is easier than replacing just the gear but the gear will fail again eventually.
the gear swap is not too difficult and there are many walkthroughs here on the forum.
you can also see the walkthroughs from Brent Franker:
http://www.bfranker.badz28.com/headlightfix/index.htm
or Rodney Dickman:
http://www.rodneydickman.com/n113.html
Of the 2 styles available, i'd go with the solid Bfranker ones because the rubber bushings have failed again on me with my Rodney kit.
The Franker kit doesn't have those issues.
Last edited by jdmvette; Mar 17, 2007 at 12:30 AM.
Night Owl for life
Joined: Nov 2003
Posts: 24,719
Likes: 4,556
From: Bugs Bunny should'a made a left turn here
the epoxy came off on mine also.
i ended up drilling several small holes around the perimeter of the casing and the lid and sliding a small cotter pin in and twist tie-ing the lid on. it's very solid now.
i ended up drilling several small holes around the perimeter of the casing and the lid and sliding a small cotter pin in and twist tie-ing the lid on. it's very solid now.
Thread Starter
Melting Slicks
Joined: Jun 2003
Posts: 2,767
Likes: 0
From: Indianapolis IN
Awesome. Should I try to take the headlight out before I remove the motor? I just went out and looked at it and it seems there's only 3 bolts holding it in? The BFranker link shows how to take it out of a Trans Am. Anybody know if there is a C5 instruction set somewhere?
Night Owl for life
Joined: Nov 2003
Posts: 24,719
Likes: 4,556
From: Bugs Bunny should'a made a left turn here
there are 3 bolts and one nut holding the motor on from the other side.
it's very straightforward when you get into it. you don't need to pull the headlight at all.
it's the same motor for the TA so it will bolt the same way in the C5.
if you get a new motor it's as simple as pulling the bolts and putting the new one on. you don't have to mess with any of the gear business. but a new one will fail on you eventually.
your stock one lasted 6 years though, so it might be worth it to you.
it's very straightforward when you get into it. you don't need to pull the headlight at all.
it's the same motor for the TA so it will bolt the same way in the C5.
if you get a new motor it's as simple as pulling the bolts and putting the new one on. you don't have to mess with any of the gear business. but a new one will fail on you eventually.
your stock one lasted 6 years though, so it might be worth it to you.
Burning Brakes
Joined: Apr 2006
Posts: 940
Likes: 0
From: Surprise Arizona
Yep, the plastic gear in the motor is stripped. Does just what you are describing and does it without warning. Get a pair of brass replacement gears from Rodney Dickman for $85. They come in a kit that includes instructions, lube, epoxy to reseal the motor housing once your break them apart to switch out the gears. The new brass gears work like a charm and should be a permanent solution to the problem. May as well do both sides while you're at it. The other one will go when you least expect or want it to...
Burning Brakes
Joined: Apr 2006
Posts: 940
Likes: 0
From: Surprise Arizona
Corvette Stories
The Best of Corvette for Corvette Enthusiasts
Top 10 Most Explosive Corvettes Ever Made: Power-to-Weight Ratio Ranked!
Joe Kucinski
150 hp to 1,250 hp: Every Corvette Generation Compared by the Specs That Matter
Joe Kucinski
8 Coolest Corvette Pace Cars (and Replicas) of All Time
Verdad Gallardo
Top 10 Corvette Engines RANKED by Peak Torque (70+ Years of Muscle!)
Joe Kucinski
Corvette ZR1X Will Be Pacing the Indy 500, And Could Probably Race, Too!
Verdad Gallardo
Top 10 Corvettes Coming to Mecum Indy 2026!
Brett Foote
Top 10 C9 Corvette MUST-HAVES to Fix These C8 Generation Flaws!
Michael S. Palmer
10 Revolutionary 'Corvette Firsts' Most People Don't Know
Joe Kucinski
5 Reasons to Upgrade to an LS6-Powered Corvette; 5 Reasons to Stay LT2
Michael S. Palmer
Burning Brakes
Joined: Dec 2006
Posts: 872
Likes: 3
From: 90% of all Fords are still on the road.....the other 10% actually made it home!
I bought my gear from Brent Franker for $45 shipped and installed it in about 30 minutes. I DID NOT use the epoxy either. I simply removed the black headlight bezel, then reached in behind the headlight itself and removed the 3 bolts & 1 nut. After removing the 3 casing screws, I removed all the broken pieces, wiped out the inside, installed the brass gear with a little more grease and screwed the lid back on. (the cover gasket stayed intact so I didn't bother with the epoxy)
It's been 4 months and not a single issue with mine. No more embarrasing noise coming from the headlight! I would go with the brass gear over another motor & plastic gear myself. After time it will definitely strip again.
Just my .02 worth
It's been 4 months and not a single issue with mine. No more embarrasing noise coming from the headlight!
I would go with the brass gear over another motor & plastic gear myself. After time it will definitely strip again. Just my .02 worth
Last edited by str8upchevy; Mar 17, 2007 at 05:43 AM.
Night Owl for life
Joined: Nov 2003
Posts: 24,719
Likes: 4,556
From: Bugs Bunny should'a made a left turn here
I bought my gear from Brent Franker for $45 shipped and installed it in about 30 minutes. I DID NOT use the epoxy either. I simply removed the black headlight bezel, then reached in behind the headlight itself and removed the 3 bolts & 1 nut. After removing the 3 casing screws, I removed all the broken pieces, wiped out the inside, installed the brass gear with a little more grease and screwed the lid back on. (the cover gasket stayed intact so I didn't bother with the epoxy)
It's been 4 months and not a single issue with mine. No more embarrasing noise coming from the headlight! I would go with the brass gear over another motor & plastic gear myself. After time it will definitely strip again.
Just my .02 worth
It's been 4 months and not a single issue with mine. No more embarrasing noise coming from the headlight!
I would go with the brass gear over another motor & plastic gear myself. After time it will definitely strip again. Just my .02 worth
the epoxy is supposed to hold the lid back on to the housing. it rarely holds.
Last edited by jdmvette; Mar 17, 2007 at 06:48 AM.
Le Mans Master
Joined: May 2000
Posts: 5,266
Likes: 15
From: Syracuse NY
Cruise-In II Veteran
.JDM... I was thinking like you to avoid the epoxy. Is there enough "meat" to use some small hex head screws in lieu of just epoxy to re-assemble?
Thread Starter
Melting Slicks
Joined: Jun 2003
Posts: 2,767
Likes: 0
From: Indianapolis IN
I did read on a few other threads that people put small screws (or even twist ties) in the housing to help hold it together.
Thanks to everyone so far for the replies! Any other advise is much appreciated!
Thanks to everyone so far for the replies! Any other advise is much appreciated!