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Headlight gear fix (highly pictorialized)

Old 07-26-2007, 01:38 PM
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St. Jude Donor '08-'09-'10-'11

Great write up.

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Old 07-26-2007, 02:00 PM
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Very nice writeup Ed
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Old 07-26-2007, 03:03 PM
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A couple of comments to supplement Patches install - as I had some problems with my install in the past that others may encounter.

If you have an older C5 the motor bolts together so it is easy to get at the gear. If, like myself and Patches, you have to "break" the case to get it apart be very careful. I had a hard time separating the parts and actually loosened the motor/worm gear in such a way that it stripped my brand new gear (plastic, not metal). I ended up having to buy a new motor (found it relatively inexensive on ebay compared to even our supporting vendors).

This leads to the second point - NAPA sells a replacement plastic gear if anyone decides they prefer the plastic over the metal. Clearly benefits to both and some may prefer plastic.

Also, you don't have to remove the headlight cover unless your arms are too big to fit in the opening under the headlight. If you do remove the cover, use something to mark the position of the screws on the headlight so you can get it aligned easily.

Have a telescoping/flexible magnet standing by. You will drop nuts/bolts into the bumper. If you're light me, you even drop the socket wrench.

This is an easy install as soon as you figure out what you're doing. Patches pictorial is perfect to get an understanding of the job.

Oh, and when you get done and have the lights set up to go one up/one down because you hooked up the lever wrong on the motor - don't let your wife watch. It gets embarassing and you have to hustle to fix it while she dashes for the video camera!!!

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Old 07-26-2007, 03:06 PM
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Very nice writeup!
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Old 07-26-2007, 03:24 PM
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Please adopt me. I can't turn a wrench to save my life.
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Old 07-26-2007, 05:59 PM
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Great write-up, thanks
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Old 07-26-2007, 06:29 PM
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St. Jude Donor '04-'05-'06-'07

The usual masterful production by Ed...

Def. needs to be a sticky... I know this issue is frequently discussed and it seems intimidating... I know I want to keep this when my time comes up.

Awesome work Ed... and THANK YOU.

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Old 07-26-2007, 09:45 PM
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Thanks for the comments, guys. I enjoy documenting my projects and fixes and I hope it helps someone down the road.

Chrisj, excellent comment - I neglected to mention about the older C5 gear cover being screwed on so that it doesn't have to be broken into as the newer version does. Some good tips there as well.

Also, I agree with jbondfl - the new brass gear is as quiet as the original plastic gear. One thing I have wondered about is how much more load it puts on the motor since it weighs several times more than the plastic gear and if that will affect the motor life.

Another thing - be sure and check how securely the bent retaining tabs hold the motor to the gear case. If it's too loose, it could create slop in the gear-to-worm engagement, causing premature gear failure due to wear. The tabs can be bent inward a bit by holding the motor on a vise and tapping the tabs in a bit with a hammer and screwdriver or similar tool.
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Old 07-29-2007, 10:11 PM
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I need to do this, my euro lights are heavier and will quit any day.

Thanks for the step by step info
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Old 07-29-2007, 10:22 PM
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St. Jude Donor '06-'07

One of the best, most complete write ups I've seen..

Thank you for the detail...
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Old 07-29-2007, 10:54 PM
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Yet another great writeup Patches! Thanks!
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Old 07-29-2007, 11:01 PM
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St. Jude Donor '05-'06-'07-'08-'09-'10

Great write-up and supporting documentation.

Some great info from chrisj as well.

Mine have the bolts so thankfully I did not have to mess with the glue.

I did not unplug mine and did not have too much trouble with the task.

Here was my worn out gear.
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Old 07-29-2007, 11:12 PM
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I hope you never loose your affinity for the C5. Without doubt one of the cleanest and most documented repair/fix/ general knowledge base guys on the forum.

Amazing some of the highly detailed pics you've got there my friend. And for me to take a wild guess on the QTEC's, YEP - You had a pic and fix..... Amazing - simply amazing!

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Old 07-29-2007, 11:21 PM
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Looks familiar
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Old 07-30-2007, 01:16 AM
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Very nice write-up.
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Old 07-30-2007, 01:22 AM
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St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12

Originally Posted by VRROOOM2 View Post
Nice job Ed!! Thanks for taking the time and putting forth the effort!!

Simply awesome Ed! I bet Mrs. Patches will not have any problems with this for a long time
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Old 07-30-2007, 01:41 AM
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I remember the first time I found this forum I was just browsing through the different threads and came across the write up patches did on
installing the hurst shifter in the C5, what a great write up that was and full pics to go with it, right than and there I knew this was the place to go for tech knowledge.

patches I just want to say thank you for taking your time to post such good information that anybody can follow. Always well done and illustrated.

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Old 07-30-2007, 01:47 AM
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I love such detailed "how to's" complete with great photos. Thanks for the public service.
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Old 07-30-2007, 05:36 AM
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St. Jude Donor '08-'09-'10-'11-'12-'13-'14-'15-'16

Another excellent post Ed!

This is another example of your willingness to share your experiences with us here on the forum and make it the great resource it has become. We all benefit from folks such as yourself.

Mazal Tov my man!
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Old 07-30-2007, 06:37 AM
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That is a great writeup. Most of us will have this project at some point. Because of people like you we will be able to do it.
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