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Old Oct 8, 2010 | 08:58 PM
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Default headlight motors

Just passing on some info. Just had my left HL motor replaced and now my chrome cover for it won't fit. Apparently, GM had so many problems with those motors that they changed the design; now the aftermarket vendors need to create a new cover. Just wanted to let everyone know and hope this isn't old news.
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Old Oct 9, 2010 | 09:51 AM
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Why didn't you just replace the gears, instead of the entire motor Doug? Cheaper, more reliable, and your cover would still fit.
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Old Oct 9, 2010 | 10:37 AM
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Just got my replacement gear's from Top Down Solutions gotta do both of mine this weekend!!
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Old Oct 9, 2010 | 10:45 AM
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Originally Posted by doug doo wop
Just passing on some info. Just had my left HL motor replaced and now my chrome cover for it won't fit. Apparently, GM had so many problems with those motors that they changed the design; now the aftermarket vendors need to create a new cover. Just wanted to let everyone know and hope this isn't old news.
Any pics of the new motor in comparison to the old one?
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Old Oct 9, 2010 | 10:51 AM
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after i changed my gears my lights may or may not come up, most of the time they will not come up. i don't know if it is an alignment issue or what. does anyone have a pic of the area where the motor and are connect together or the position on the are on the stops? if i can't figure it out then i will be off to the stealership cause it is very embarrassing to have to get out and open them manually.:o....
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Old Oct 9, 2010 | 10:57 AM
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Originally Posted by hdff
after i changed my gears my lights may or may not come up, most of the time they will not come up. i don't know if it is an alignment issue or what. does anyone have a pic of the area where the motor and are connect together or the position on the are on the stops? if i can't figure it out then i will be off to the stealership cause it is very embarrassing to have to get out and open them manually.:o....
Same thing happend to mine. Upon inspection, I found that the end plate that you epoxy back on did not hold. I pulled it out, reglued it and then put 3 wire ties around it. The ties are slightly visible, but the light works perfect now. Some day I will replace the white ties with black ones.

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Old Oct 9, 2010 | 11:13 AM
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Originally Posted by 4 KRUSIN
Same thing happend to mine. Upon inspection, I found that the end plate that you epoxy back on did not hold. I pulled it out, reglued it and then put 3 wire ties around it. The ties are slightly visible, but the light works perfect now. Some day I will replace the white ties with black ones.

the gear that i bought came with a metal piece that went across the cover to help keep this from happening. i haven't taken it back apart yet but i can't believe that this would happen to to both sides, but it is something i will check out when i get a chance to pull them back out...
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Old Oct 9, 2010 | 08:13 PM
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I just ordered a kit from Brent Franker..I will tk pics before removing motor and I think I'll use tie wraps along w/ the epoxy.
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Old Oct 9, 2010 | 08:19 PM
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Take three washers and slightly bend one side down on each washer, place the bolts through the washers and align the bent part of the washer over the cover of the motor, tighten your bolts down on the cover and notice the wonderful way the washers hold the the motor cover in place. Did this procedure on both of my motors and it works fine!
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Old Oct 9, 2010 | 08:23 PM
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Originally Posted by mjmc1273
Take three washers and slightly bend one side down on each washer, place the bolts through the washers and align the bent part of the washer over the cover of the motor, tighten your bolts down on the cover and notice the wonderful way the washers hold the the motor cover in place. Did this procedure on both of my motors and it works fine!
ok, I'll epoxy it and try this washer trick..thanks
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Old Oct 9, 2010 | 08:52 PM
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Originally Posted by sneakelman
Why didn't you just replace the gears, instead of the entire motor Doug? Cheaper, more reliable, and your cover would still fit.

HI Tim, I didn't know you could replace the gears. Are we talking about the same thing. My mechanic never said anything about replacing any gears;I'll have to ask him.
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Old Oct 9, 2010 | 09:29 PM
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Originally Posted by doug doo wop
HI Tim, I didn't know you could replace the gears. Are we talking about the same thing. My mechanic never said anything about replacing any gears;I'll have to ask him.
yes you can replace the weak plastic gears with hardened aluminuim or brass. alot of people have had good luck doing it. mine work fine when they work with the new gears. you can replace both gears for ~ $80
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Old Oct 9, 2010 | 09:29 PM
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Just finished both gears very easy mod , I have the metal housing so no glueing back together.
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Old Oct 10, 2010 | 07:16 AM
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Originally Posted by doug doo wop
HI Tim, I didn't know you could replace the gears. Are we talking about the same thing. My mechanic never said anything about replacing any gears;I'll have to ask him.
Either he doesn't know you can replace the gears, or he screwed you Doug. I'd guess the latter.
If he replaces the gears, then he will never see you again for another motor.
According to Rodney Dickman(THE man when it comes to the GM headlight motor) the motor design is dam near bullett proof. He has only ever seen 3 motors fail out of tens of thousands. The flaw is the plastic gears. Over time, the teeth break off due to stress being applied as the motor tries to continue to turn for a moment when it hits the stops. Replacing the gears with brass, or aluminum, ones makes for a permanent fix.
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Old Oct 10, 2010 | 07:33 AM
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ive replaced gears and such in numerous firebird and trans am's ive had, no problems with the vette as of yet! deff use the brass/aluminum gears, i stripped a replacement plastic one in a week
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Old Oct 10, 2010 | 08:04 PM
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Originally Posted by sneakelman
Either he doesn't know you can replace the gears, or he screwed you Doug. I'd guess the latter.
If he replaces the gears, then he will never see you again for another motor.
According to Rodney Dickman(THE man when it comes to the GM headlight motor) the motor design is dam near bullett proof. He has only ever seen 3 motors fail out of tens of thousands. The flaw is the plastic gears. Over time, the teeth break off due to stress being applied as the motor tries to continue to turn for a moment when it hits the stops. Replacing the gears with brass, or aluminum, ones makes for a permanent fix.
The mechanic is a club member and friend but I will ask him about changing gears. He also said that it is a fairly frequent problem and just replaced one recently. That is why GM changed the design which is quite different in size from the old one and my chrome cover won't fit.
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Old Oct 10, 2010 | 09:05 PM
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Originally Posted by doug doo wop
The mechanic is a club member and friend but I will ask him about changing gears. He also said that it is a fairly frequent problem and just replaced one recently. That is why GM changed the design which is quite different in size from the old one and my chrome cover won't fit.
He is right on one point, it is a common thing. But GM didn't change the design to fix the flaw. The internal design of the motor itself is the same, and the parts are the same. They just changed the body.
They did the same thing in the mid 80's, again in the 90's, and once again when they changed the Corvette/Trans-Am/Firebird headlight motors.
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Old Oct 11, 2010 | 09:36 AM
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Good info. I went with brass gears and haven't had a problem since.
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Old Oct 11, 2010 | 11:43 AM
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Thanks for the info guys
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