I've searched and read about the gear problems but not sure if that is what I'm having. Mine started with my right headlight not coming up. The light was on but it did not raise. I turned the lights off and manually raised it. When I turned the lights on the left one came up as expected. When I turned them off, they both went down. I turned them back on again and they worked normally as if nothing had happened.

A few tries later, the right one would not raise again. This time I did it differently. I manually raised the right headlight with the left light already up and the lights burning. Again when I turned them off, they both went down but the right lights motor continued running for about 10 seconds and sounded terrible.

Now the strange part. When I turn on the light switch to the first position that normally just turns on the fog lights (unless I've completely lost it), both lights pop up but are not on. If I turn the switch back off, both lights go down and the right motor grinds again. Turn it back on to the first position, both lights up but not on. Turn the switch all the way on and they both come on. Turn it off, they go down and once again the grind.

Sorry for all the detail but not sure what important to know and what isn't. Is this a gear replacement problem or module?

Thanks!

 

Well PART of the problem is that your gears are shot. I would start there and after replacement THEN see if you have other issues.

rr

 

Worn gears can cause the other issues you're having.

replace the right gear and see where you are. It'll almost certainly fix everything

 

Thanks. I will order a kit and see what happens. I'm guessing I should go with the metal gear instead of the oem nylon.

 

If you put oem gears back in it, it will just happen again. Personally I would go ahead and replace both of them with brass gears cause the other one is going to go also, just a matter of time.

 

Good Point. I'll do that. I was just trying to order them from Rodney's site but it won't add anything to the cart and get's and error. I'll try again tomorrow.

 

Replace gear in right motor and also lube all hinges/pivot points.

Try using the fog light switch on the dash to turn on your fog lights.

 

having this exact problem, every reply on this forum was to replace the gears!! good luck

 

These might help you replace that gear:

http://forums.corvetteforum.com/c5-g...orialized.html

http://forums.corvetteforum.com/c5-g...placement.html

 

^^^ I agree. I had the same problem with my 97 Formula. I replaced it with the brass gear and didn't have a single problem with it for the rest of the time I had that car, which was until I bought my 02 Trans Am in 04.

 

I had a the same problem and replaced the gear with a metal one as well. My gears are no longer grinding but now my left head light will not flip open. Just liked you described as well. If ii turn the headlight motor manually just one click, then go back in the car and use the switch the headlight will catch and flip up. This will last only for a few hours however. I checked the headlight motor and the motor did not come apart "had a few epoxy problems already" any suggestions?

 

It sounds like it's getting torqued down so much it can't spin the worm gear to open the light. You could try filing down the metal gear a little or perhaps adding a resistor to the motor would fix that... I don't know exactly how they work, but the motor needs to be weaker so it doesn't torque down so much.

 

EXACTLY the problem I'm currently having with the left headlight on my '04 -- any further thoughts on this?

In my case I have zero noise suggesting a gear problem. The symptoms are more like: when the motor's at the rest position, there is a switch somewhere whose contacts are *juuuust* a hair apart, and the slightest movement of the manual **** allows the contacts to close and power the motor.

I have no idea what the actual arrangements inside the unit are like, but my instincts are telling me this isn't a gear issue, but a contact issue. Anyone know what the electrical internals look like? Think I'm out in left field? Or is a non-gear problem a real possibility?

Thanks!