Hello!
I have a 2003 Convertible and have been back and forth with the dealership regarding my popup headlights. The first problem was the infamous gear replacement which was done by a Corvette tech at a Chevy dealer and replaced with brass gears. Then I have the problem where the drivers headlamp would go up and down then come back up half way. Learned that was because the headlight frame had been bent some how and the dealer repaired, in addition to the passenger side headlight motor coming apart where the adhesive was used to reassemble the motor after the headlight gear replacement, dealer also repaired. My latest issue is that the headlight will not come up when the switch is flipped, the lights go on in the housing and a noise is made (maybe the lamps coming on) but the lights do not physically move unless I take off the manual control cover and ever so slightly turn the **** to release the tension on the motor then the lights work perfectly for the rest of the evening no matter how many times I uses the light then the next day its the same story. I cannot figure out for the life of me if there is maybe an adjustment to help the lights from putting so much tension on the motor when the lights are lowered or if a component has failed, even though the lights seem to function after the tension is released.
Thank you for all your help!
-Jake

 

Rodney Dickman's kits include a special steel brace to prevent this from happening. He also sells just the brace and urethane glue to upgrade previous repairs. Check it out here