A couple of weeks ago, I noticed a grinding sound in the left headlight of my 2000 convertible. Someone on these forums kindly and correctly identified the problem as worn teeth on the cheap, plastic, original-equipment gear. I replaced the gears in both headlights using the brass ones from Rodney Dickman. I tested the headlights about a dozen times to ensure that they were working properly and were properly adjusted. Everything worked perfectly… for about 3 days. Then one day, as I was driving, I turned my lights on and off manually (something I don’t normally do since I have Twilight Sentinel). Both lights popped up normally. When I turned them off, both lights went down but the left light popped back up even though the light was off. I turned them on and off several times and every time the left headlight popped up again after going down and turning off.

So, I removed the left headlight assembly (again, which is sort of a pain in the butt) and looked it over. Everything seemed OK except I noticed that the white rubber bumper on the stop was worn and had a small split in it. As suggested on another thread on these forums, I turned the white rubber bumper around so that the headlight had a new surface to close on. I readjusted the headlight in the open position to about 1 mm from the stop (per Dickman’s written instructions) and reinstalled the headlight assembly. Everything worked fine again… for a while. Then just today, I noticed that the headlight cover wasn’t quite aligned with the hood and fender. It was only slightly out and some owners might not have even messed with it, but I am kind of obsessive that way; it HAS to be right! So I turned the lights on to access the adjustment screws; but before adjusting them, I turned the lights off again to eyeball the fit prior to making the adjustment. When I turned the headlights off, once more the left one went down, turned off, and then popped back up again. What am I doing wrong?

 

The bumper may be worn to the extent it cannot function whether turned around or not.

Just a note - you do not have the manual **** turned too tight do you?

 

I don't think so. I have turned the manual **** to the loosest setting that it will go to. Same thing. Headlight pops back up.

 

There is a TSB out on this, here it is:

Document ID# 728272
2000 Chevrolet/Geo Corvette


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Tech - Left Headlamp Door Does Not Stay Closed #00-08-42-002 - (May 30, 2000)
Left Headlamp Door Does Not Stay Closed (Shim Headlamp Door Motor/Actuator and Replace Insulators)
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


Parts are expected to be available from GMSPO, 6/15/00.

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

N3231
Actuator Assembly, Left Front Headlamp - Replace

Note: Also Referred to as "Motor Assembly"
0.5 hr

 

^^^^^^^^^^
Had the same problem................the forum helped me out too! Easy fix!

 

Great reply from Oldvetter!

 

Great! Thanks for the info. Looks like I need to see my Chevy dealer first thing in the morning.

 

When I first got my vette the right headlight would pop up and down unprecictably and randomnly. Really weird. The dealership fixed it under warranty....no idea on $$$.

This could be related, but maybe not

 

I thought I knew where to put the washers, but I also thought that a diagram would be nice. So I searched on the TSB and found a thread on these forums addressing the same issue. So in case anyone else is having this problem, go to the address below to get the version with the diagram. I guess it's not rocket science, but still, I like to know that I am putting the parts where they belong.

http://forums.corvetteforum.com/show...p?p=1561292970

 

I have had the parts on order since August 10... seems GM has run out of washers.

 

After about a 10-day jerk around, I finally got those 3 little washers and the 2 insulators (as GM refers to the little rubber "bumpers") and put them in yesterday. Both headlights work like a charm! Again, I want to thank you for your excellent advice. Besides saving money, it feels good to be able to take care of these minor things myself.

 

I installed the new insulators and washers per the TSB but I am sorry to say that after a few weeks of trouble-free operation, my problem is back; the left headlight door closes and then pops up again about halfway . I am not real fond of the looks of the C6, but those fixed headlights are starting to look real good to me about now. What am I saying? Clearly, I am delerious. Does anyone have any suggestions as to what my next action should be? Please don't say trade it on a C6... they don't yet look THAT good to me.