Hi guys, another headlight gear removal thread.
I have a 2002 Z06 so the one with the plastic cover, I will be replacing both sides, but my right headlight gear is the one making the noise.
Ihave purchased Rodney Dickman/s updated kit that includes the rubber bushing. I will not be taking the whole headlight assembly out. I will taking the plastic housing out along with the top of the headlight.
When I remove these should i be concerned about any alignment issues? Mostly concerned with top of headlight cover contacting bumper or hood. Also, when headlight gear is removed, doesn't the headlight like the freefall, or rotate? I've seen videos where it rotates down on an axis, but doesn't look like it needs realigned. Any advice is appreciated.

Thanks,
Logan

 

popo, I recommend you remove the headlight units during the proposed mod. It is not a difficult job, takes about 45mins-1 hour to do each side. Just uses protective rags/towels around the headlight units during removal/installation to prevent any accidental damage to the paint.

The instructions that come with the Rodney Dickman brass gear kit are excellent, if you follow them you cannot go wrong.

The only minor adjustments you may have to make are to the plastic cowls that go over the headlights. When refitting them, leave the screws fingertight so you can slide the cowls so that they are exactly in the center of the space they fit into., and then when you are satisfied, tighten the screws to fully secure the cowls.

It is my recommendation that you do the passenger-side headlight first, simply because it is slightly easier if you are right handed to get at the bolts. The driver-side is just a bit more awkward but having already done the passenger side you will know what you are doing by now.

Replace or flip the 4-white-plastic stops on each headlight while you are there.

Here is a "how-to" video that you may or may not have seen before.



Good luck, and let us know how you fare.








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Thank you so much for the quick response and for the information. I will most likely not get to it this weekend, but whenever you remove the headlight, does it realign in the same position with the screws or will it need a realignment?

Thanks,
Logan

 

These step-by-step directions are fantastic and may answer your questions.

 

Here's my $0.02:

I did not remove the entire headlight assembly, nor do I believe this would be helpful in any part of the removal/installation.

When you remove the arm that connects the headlight assembly to the motor shaft, the headlight assembly will drop down into the bumper. This gives you plenty of space to access the headlight motor. There's no realignment required on assembly, as long as the headlight motor shaft is in the same position as it was before disassembly.

Also, make sure your headlight is in the correct position when you're finished. I started with my headlights down and used the manual **** to turn the headlight I was going to work on to the up position. When I went to put the headlight assembly back together, I somehow wound up with the headlight fully down again. Eventually, I realized I put the arm that attaches to the headlight motor shaft on upside down (180* off). I flipped it around to get my headlight back to the up position, and then turned the headlight back down with the manual ****.

After I was finished, I cycled the headlights once and they synced up perfectly together. It's really quite an easy process, the most difficulty I had was removing the cover off the plastic headlight motor housing. I wound up using a razorknife and a hammer to separate the cover without gouging it with a screwdriver.

 

Excellent step-by-step directions. (Like seavette, patches also just loosened the headlight units and moved them out of the way, so maybe that is a valid method, I removed them because it is so easy to do so and makes for plenty of elbow room while also removing any chance of paint damage)




The removal of the plastic motor cover was my only moment of caution too. I was afraid of breaking the cover, but they are quite sturdy and quite a lot of force can be used without a problem......once you have broken the glue seal the cover pries off with a little encouragement.


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Remove the headlight cover. Then remove the 2 aft hinge bolts. Let the headlight assy roll into the fender forward. You'll have access to everything you'll need to get to.



The actuator will be easy to remove this way. I found this to be the easiest way to get to it.





Good luck. Easy job.

 

Wow, thank all of you guys for the helpful information. Also noticed that my headlights pop up when I turn the stalk to the second switch, will changing gear solve this?

 

Yes, it should.

I just did mine and just removed the motor, not the whole headlight. I have big hands and was able to remove with no real problems.