I just replaced the plastic gears with brass. After approx. one week, the driver's side started popping back up after it was turned off. Help!
Robert

 

Here is answer, thanks to DeeGee:

Heres the TSB

Its a simple fix with a couple of washers



Subject: Left Headlamp Door Does Not Stay Closed (Shim Headlamp Door Motor/Actuator and Replace Insulators)
Model Year: 2000 Chevrolet Corvette
Condition
Some customers may comment that the left front headlamp door does not remain closed after the headlamps are turned off. Others may comment that the left headlamp door closes when the headlamps are turned off, but then reopens. In either case, the right headlamp door operates properly.

Correction

Important

The following information applies to the left front headlamp door motor/actuator only. It does not apply to and should not be performed on the right front headlamp door motor/actuator.







Install one washer (2) between the left headlamp door motor/actuator (1) and the mounting bracket (3) at each of the three attaching bolt locations. Also replace the insulator (4) on each of the two mounting bracket travel stop tabs (5) as shown. For information on headlamp motor/actuator removal, see the Headlamp Motor/Actuator Replacement procedure in the Lighting sub-section of Body & Accessories in the appropriate Service Manual.
Parts Information
Part Number Description Qty Per Vehicle
11505463 Washer 3
16524060 Insulator 2

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I would also get the Insulators, they may be different. Besides, having replaced the headlight gears, you know that getting this assembly out is not a "walk in the park", better to fix it once and all.

 

Sometimes just replacing the stops will fixed it without taking anythng apart -

 

Make sure where the housing is glued together by the gear didn't come apart.