i have an 04 and having problems with the headlight poping half way up after i turn off the lights. im told its a bushing that cant be purchased without buying the whole headlight assembly and other things as well. long story short,they want to charge me $1000 or more for a $5 bushing
any input on a better fix???????? thanks in advance

 

you need a motor limit bushing and its most likely still good but a little mushed on one side. take it out and flip it over. glue it back on the mount and you should be good to go.

 

If you are talking about this fix (posted by DeeGee):
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Number: 00-08-42-002
Subject: Left Headlamp Door Does Not Stay Closed (Shim Headlamp Door Motor/Actuator and Replace Insulators)
Model Year: 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

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And the washers are not available, I would think any plastic washer (of the correct diameter to fit the bolts) would do.

 

can the insulators be purchased anywhere? mine are in pretty bad shape

 

Try your Chevy dealer, if he doesn't have them, try emailing:

parts@fichtnerchevrolet.com

 

as this thread is pretty old the pic doesn’t work. Mine is doing this too.

could someone show me where the washer goes or a completed fix?

 

Take off the black headlight surround trim first.
You'll see the three bolts that hold the motor onto the side of the housing. 10mm wrenches. The washers go between the motor mounting legs and the housing framework, so you're spacing the motor out away from the housing.
Then, use one of the two spare grey/white bumpers from on top of the housing on the limit stop inside the framework that the motor arm stops against.

 

Not sure if this is what you need.

https://rodneydickman.com/product_in...roducts_id=309