2002 headlamp door mechanism
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3rd Gear
Joined: Feb 2012
Posts: 3
Likes: 0
From: Oro Valley Az
2002 headlamp door mechanism
I have a 2002 convertible, Right headlight door mechanism continues to turn and make grinding noise when closing. Door drive motor keeps running for 4 seconds after door is closed. Looks like I have to replace the complete door mechanism. Any help or suggestions would be greatly appreciated. Thanks Walt
Advanced
Joined: Feb 2012
Posts: 53
Likes: 2
From: Alexandria VA
Do your lights open and close? I'd take apart the housing and check out the gears...a lot of guys put brass gears in b/c they are way more durable than the plastic ones, but I think if you just put in a new gear regardless that should fix it.
http://rodneydickman.com/catalog/pro...6c51859c231568
http://rodneydickman.com/catalog/pro...6c51859c231568
Tech Contributor
Joined: Dec 2003
Posts: 19,384
Likes: 87
From: Horncastle Lincolnshire, England
2023 C5 of the Year Finalist - Unmodified
Those are classic symptoms for headlight gear failure. No need to replace anything other than the gears. Some members suggest doing both at the same time as it's easier 2nd time around
Take a look at posts #2 and #22 in the DIY sticky in C5 Tech for how to do it.
http://forums.corvetteforum.com/c5-t...l-in-here.html
I had a new headlight motor module fitted under warranty and both mine are still going strong. I diabled Twilight Sentinel so the lights are not always popping up and down so mine get less stress than some. I do have a set of Rodney Dickman's brass gears ready to go in if they fail again. Rodney's kit has a specially designed bracket to make sure the module can be reassembled properly.
Take a look at posts #2 and #22 in the DIY sticky in C5 Tech for how to do it.
http://forums.corvetteforum.com/c5-t...l-in-here.html
I had a new headlight motor module fitted under warranty and both mine are still going strong. I diabled Twilight Sentinel so the lights are not always popping up and down so mine get less stress than some. I do have a set of Rodney Dickman's brass gears ready to go in if they fail again. Rodney's kit has a specially designed bracket to make sure the module can be reassembled properly.
Last edited by DeeGee; Apr 30, 2012 at 03:16 AM.
Instructor
Joined: Apr 2011
Posts: 161
Likes: 14
From: Florida
Those are classic symptoms for headlight gear failure. No need to replace anything other than the gears. Some members suggest doing both at the same time as it's easier 2nd time around
Take a look at posts #2 and #22 in the DIY sticky in C5 Tech for how to do it.
http://forums.corvetteforum.com/c5-t...l-in-here.html
I had a new headlight motor module fitted under warranty and both mine are still going strong. I diabled Twilight Sentinel so the lights are not always popping up and down so mine get less stress than some. I do have a set of Rodney Dickman's brass gears ready to go in if they fail again. Rodney's kit has a specially designed bracket to make sure the module can be reassembled properly.
Take a look at posts #2 and #22 in the DIY sticky in C5 Tech for how to do it.
http://forums.corvetteforum.com/c5-t...l-in-here.html
I had a new headlight motor module fitted under warranty and both mine are still going strong. I diabled Twilight Sentinel so the lights are not always popping up and down so mine get less stress than some. I do have a set of Rodney Dickman's brass gears ready to go in if they fail again. Rodney's kit has a specially designed bracket to make sure the module can be reassembled properly.
Melting Slicks
Joined: Jun 2004
Posts: 2,453
Likes: 81
From: Fishin' Pole FL
Just did the gear install last Friday on my passenger side. There's more than one way to do it. I reviewed both posts mentioned above. I did not remove the entire assembly. Here are a couple ideas that may help.
Use quality tools if you are going to remove the shoulder bolts that the light hinges on rather than removing the whole assembly. They have loctite on them.
Sharpen the tip of an old flat blade screwdriver to use to get the cover started when prying it off, its glued on.
The main thing once the cover is off is not to get any grease on the surface where the glue goes. Just getting the broken pieces of the gear out is good enough when cleaning.
There's four plastic stops in the assembly, the two that stop the arm on the motor wear out on the edges, you may want to swap them with the two on the top, they don't see any wear per se. If they are loose you will want to tighten them up somehow.
I don't think you can buy these parts seperately.
Good Luck, I hope your work goes smoothly.
Here is the kit:
Here is what breaks: Because it stops at the same place on the gear every time.
Use quality tools if you are going to remove the shoulder bolts that the light hinges on rather than removing the whole assembly. They have loctite on them.
Sharpen the tip of an old flat blade screwdriver to use to get the cover started when prying it off, its glued on.
The main thing once the cover is off is not to get any grease on the surface where the glue goes. Just getting the broken pieces of the gear out is good enough when cleaning.
There's four plastic stops in the assembly, the two that stop the arm on the motor wear out on the edges, you may want to swap them with the two on the top, they don't see any wear per se. If they are loose you will want to tighten them up somehow.
I don't think you can buy these parts seperately.
Good Luck, I hope your work goes smoothly.
Here is the kit:
Here is what breaks: Because it stops at the same place on the gear every time.
Last edited by dndrsn; Apr 30, 2012 at 01:19 PM.
