Headlight gear replacement
Thread Starter
Burning Brakes
Joined: May 2004
Posts: 929
Likes: 45
From: Wayne NJ
Headlight gear replacement
My Rt headlight when retracting is making a lot of noise so after doing some research found out it’s the headlight motor gear. I’m a little hesitant about trying to do the repair myself. First repair on my C5 in 16 years.
Race Director
Joined: May 2003
Posts: 14,137
Likes: 2,984
From: Iowa
St. Jude Donor '03 thru '26
Don't be scared of this job, it's pretty easy to do. It comes with instructions.
http://www.rodneydickman.com/corvette.html
http://www.rodneydickman.com/corvette.html
Instructor
Joined: Jan 2017
Posts: 169
Likes: 22
From: Shelton WA
Yep-easy cheesy. As others have said, lots of detailed instructions/videos out there. I opted for the brass gears tho instead of the plastic. IIRC when i did mine last year, several places make the kits, so do your research about them all and get the one u want (and might as well do both sides while you are at it-the other side is probably about due as well, and might as well do it when its fresh in your mind). Good luck and have fun with it-it's not difficult at all 
Le Mans Master
Joined: Sep 2013
Posts: 8,900
Likes: 1,074
From: Wisconsin
If you don't want to try to replace the gear, you can get the whole remanufactured assembly for almost the same price.
https://www.summitracing.com/parts/a...xoCZpgQAvD_BwE
https://www.summitracing.com/parts/a...xoCZpgQAvD_BwE
Burning Brakes
Joined: Jan 2011
Posts: 779
Likes: 67
From: Simi Valley Ca
St. Jude Donor '12
If you don't want to try to replace the gear, you can get the whole remanufactured assembly for almost the same price.
https://www.summitracing.com/parts/a...xoCZpgQAvD_BwE
https://www.summitracing.com/parts/a...xoCZpgQAvD_BwE
https://www.summitracing.com/parts/a...9/applications
Melting Slicks
Joined: Jan 2009
Posts: 3,275
Likes: 739
From: Miami FL
It seems you probably have a broken plastic gear.
Get a kit like this one (pay attention because there are 2 different kits: one for "97 to early 2000" and another for "late 2000 to 2004") and follow these step-by-step directions. You'll save money and they will last forever.
It would be wise to replace as well the rubber bump stops in both sides (#4 in diagram below). You can get them here.
There is a TSB, that calls for shimming the driver's side motor. The parts needed for this are included in the above mentioned kit (#2 in diagram below).
Last edited by GCG; Mar 24, 2019 at 12:44 AM.
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Melting Slicks
Joined: Nov 2008
Posts: 3,146
Likes: 203
From: Edmonton Alberta, Canada
If you don't want to try to replace the gear, you can get the whole remanufactured assembly for almost the same price.
https://www.summitracing.com/parts/a...xoCZpgQAvD_BwE
https://www.summitracing.com/parts/a...xoCZpgQAvD_BwE
WOW, that is cheap...thanks for sharing!
Race Director
Joined: May 2003
Posts: 14,137
Likes: 2,984
From: Iowa
St. Jude Donor '03 thru '26
Originally Posted by JR-01 
If you don't want to try to replace the gear, you can get the whole remanufactured assembly for almost the same price.
https://www.summitracing.com/parts/a...xoCZpgQAvD_BwE
If you don't want to try to replace the gear, you can get the whole remanufactured assembly for almost the same price.https://www.summitracing.com/parts/a...xoCZpgQAvD_BwE
Le Mans Master
Joined: Sep 2013
Posts: 8,900
Likes: 1,074
From: Wisconsin
http://www.amazon.com/Headlamp-Headl...rolet+Corvette
www.amazon.com/dp/B07DHPYY18/ref=psdc_318323011_t1_B07DHN4L3V
shop around for the best price.
www.amazon.com/dp/B07DHPYY18/ref=psdc_318323011_t1_B07DHN4L3V
shop around for the best price.
Last edited by JR-01; Mar 24, 2019 at 06:45 PM.
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Lots of members have done their own headlight gear replacement - plenty of videos/write-ups about it.
Advanced
Joined: Jan 2019
Posts: 86
Likes: 25
Just did this job last night. It’ll take 2 hours if you take your time, and you should leave at least an hour or two of dry time in between. Then not use the headlight for the first day or so if possible.
Idk if you are interesting in saving money, but I just bought a gear on Amazon for $22 that was a discount due to discoloration. Not sure if they are still for sale on there. Then I bought the double bubble glue for $8 or so. Total cost of $30 instead of $50. Not a big deal. Bought a kit for the first headlight but thought I would save on the 2nd after understanding the process.
Edit, still for sale: Corvette C5 Firebird Headlight Motor Repair Aluminum Gear Upgrade https://www.amazon.com/dp/B01DCG2KRO/ref=cm_sw_r_cp_api_i_kjgMCbGB51V73
Idk if you are interesting in saving money, but I just bought a gear on Amazon for $22 that was a discount due to discoloration. Not sure if they are still for sale on there. Then I bought the double bubble glue for $8 or so. Total cost of $30 instead of $50. Not a big deal. Bought a kit for the first headlight but thought I would save on the 2nd after understanding the process.
Edit, still for sale: Corvette C5 Firebird Headlight Motor Repair Aluminum Gear Upgrade https://www.amazon.com/dp/B01DCG2KRO/ref=cm_sw_r_cp_api_i_kjgMCbGB51V73
Last edited by Tenshots1; Mar 25, 2019 at 01:10 AM.
Melting Slicks
Joined: Jan 2009
Posts: 3,275
Likes: 739
From: Miami FL
...Idk if you are interesting in saving money, but I just bought a gear on Amazon for $22 that was a discount due to discoloration. Not sure if they are still for sale on there. Then I bought the double bubble glue for $8 or so. Total cost of $30 instead of $50. Not a big deal. Bought a kit for the first headlight but thought I would save on the 2nd after understanding the process...
This is fundamental to reinforce the motor after glueing back its cover. It is designed to take away the forces from the gearbox plastic cover, especially each time the motor reaches its travel ends (which are hit very hard). Without it, the glue will likely fail.
It can be separately bought. Take a look a this for more details.
IMO, Rodney Dickman's kits (links above in Post 8) are the most complete and well thought out sets available.
Last edited by GCG; Mar 25, 2019 at 01:46 AM.
Advanced
Joined: Jan 2019
Posts: 86
Likes: 25
It seems you are missing a critical component: the steel T-Brace with plastic bushing.
This is fundamental to reinforce the motor after glueing back its cover. It is designed to take away the forces from the gearbox plastic cover, especially each time the motor reaches its travel ends (which are hit very hard). Without it, the glue will likely fail.
It can be separately bought. Take a look a this for more details.
IMO, Rodney Dickman's kits (links above in Post 8) are the most complete and well thought out sets available.
This is fundamental to reinforce the motor after glueing back its cover. It is designed to take away the forces from the gearbox plastic cover, especially each time the motor reaches its travel ends (which are hit very hard). Without it, the glue will likely fail.
It can be separately bought. Take a look a this for more details.
IMO, Rodney Dickman's kits (links above in Post 8) are the most complete and well thought out sets available.
Racer
Joined: Jul 2011
Posts: 462
Likes: 123
From: Ozark Alabama
If you want to save even more money you can just move the gear that is in there 180 degrees and put it back together. It only uses half of the gear. I did this a couple of years ago to my drivers side and it hasn't given me any trouble since. I figure if I can get 15 more years out of it I will be happy and if it fails I can always get the metal gear. Good Luck
Racer
Joined: Mar 2013
Posts: 477
Likes: 48
If you want to save even more money you can just move the gear that is in there 180 degrees and put it back together. It only uses half of the gear. I did this a couple of years ago to my drivers side and it hasn't given me any trouble since. I figure if I can get 15 more years out of it I will be happy and if it fails I can always get the metal gear. Good Luck
You can just pull the arm off of the motor and turn the adjustment **** until the flat side of the shaft is 180 DEG--then re-install the arm, also it's a good idea to check the bump stops for wear and either turn them over or replace them. I did this to mine and they are working like new -- cost me $0.00.
Melting Slicks
Joined: Jul 2006
Posts: 2,332
Likes: 31
From: Silver Spring MD
Tried that --- didn't work
If you want to save even more money you can just move the gear that is in there 180 degrees and put it back together. It only uses half of the gear. I did this a couple of years ago to my drivers side and it hasn't given me any trouble since. I figure if I can get 15 more years out of it I will be happy and if it fails I can always get the metal gear. Good Luck
When I tried reversing the gear the headlight made the grinding noise in the other direction. You can get the Dorman replacement gear for about $12 at Advance Auto online after searching for a 20% or 30% coupon code and picking it up at a local store. Most auto parts places have the Dorman plastic gear. I have heard too many stories on here of people using the metal gears and having the headlight stuck because the worm gear gets stuck with the metal drive gear. My original plastic gear lasted 20 years and I drive at night so I am not worried that I will have to replace it in the near future.
Heel & Toe
Joined: Nov 2017
Posts: 23
Likes: 1
From: Colchester VT
2000 C5 corvette headlifgt problem
I just replaced my driver side headlight gear with a brass gear. All went well until I buttoned up and turn the power on.
Loud grinding noises and the head light was shaking up and down.
I thought I had destroyed the gears.
I removed the motor and tried lights on - lights off with the motor laying on top of wheel well.
Passenger side OK
Motor runs much longer than the passenger side a finally stops.
Then I turn lights off. Passenger side operates correctly. The motor runs and runs in the oposite direction. and finaaly stops.
It appears I did something wrong.
Any help is appreciated
I just replaced my driver side headlight gear with a brass gear. All went well until I buttoned up and turn the power on.
Loud grinding noises and the head light was shaking up and down.
I thought I had destroyed the gears.
I removed the motor and tried lights on - lights off with the motor laying on top of wheel well.
Passenger side OK
Motor runs much longer than the passenger side a finally stops.
Then I turn lights off. Passenger side operates correctly. The motor runs and runs in the oposite direction. and finaaly stops.
It appears I did something wrong.
Any help is appreciated