My right headlight door on my 2001 C5 Coupe has an intermittent problem. Sometimes it comes up when the lights are turned on and sometimes it doesn't. There are no noises (like a stripped gear). I'm thinking it's a connection issue. Any other thoughts or suggestions?
Thank you.

 

I have a very similar problem with the driver's headlight a "99 coupe. Replaced the gear, gear was fine but replaced due to having it out and the rubber cushion was damaged, no bind, checked for a dead spot on the armature and wrote to "Corvette" mag. who suggested the module could be at fault. Replaced the module with another and still sometimes it will not function. If, I turn the manual **** and eighth of a turn the headlight will work????? Either up or down. I have check the connections till I am blue in the face and no change. I am ready to put in a new motor, don't know what else to do. I think the motor tries to "overdrive", when you take the torque out by turning the manual **** the motor works every time.
Jerry

 

Jerry- I have the same problem with my 99 coupe. Only way I can get the light to function is by turning the manual **** a bit, at which point it functions fine for a while before going intermittent. I don't drive the car much at night, so I haven't been in a rush to fix the issue but a motor was where I was leaning as well.

 

Ever since I changed to HID's mine does this sometimes, maybe 1 out of 10, I turn them off and back on and they come up. Havent really investigated it. I think it might be the lower voltage/resistence in mine. Are yours HID?

 

This problem had been a real challenge to solve. As stated I suspected the gear was bad even though I had no noise when the headlight decided to either stay down or up. When I replaced the gear the rubber cushion was damaged so that was replaced with the gear. It was not the answer so I checked the connections, all look good. I took the headlight motor apart suspecting a dead spot because of moving the **** slightly the motor would spin and the headlight would work. No dead spot on the armature apparent and I cleaned the brushes. Not the answer. After an idea from Corvette mag. I cleaned the contacts at headlight module. I thought that was the problem, then it failed again, changed the module and failure immediately---auughhh. So, now I am at the point of changing the motor. I have a good friend who will let me take his motor assembly out and put it in my car. His is a 2001 but they are interchangeable, just mine has a screw on cover and his is glued on. I will post if this is the answer to the problem. It will be a week or so before we can schedule to have both cars in my garage at the same time.

 

Have you looked into possibly the stalk being the culprit? or a corroded contact?