DW2002

Replaced the gear in my left motor a couple of weeks ago with a new nylon gear. Used Permatex 2 part plastic epoxy to glue the case back together. Worked great. Turned lamps on several times checking alingment. No problems. I have only dreiven it twice at night the last being this weekend. Left lamp wouldn't come up. Raised it manually. Now it goes up and down but makes the stripped noise on the down side. Checked the motor case and it is still glued together. Why would the new gear strip out this soon? Should I give up on the fix and just get a new motor? When it runs on I can put my hand on the manual **** and stop it with little effort so the motor itself should be ok. Love my C5 other than this problem. Thanks for any advice.

Mike Mercury

why did you replace the bad-designed nylon gear with the exact same piece?

Try the brass replacement gear... it will last a lifetime (as long as the case halves don't seperate).

'VETTE PHASE

www.rodneydickman.com

- online ordering
- electrical
- scroll down to "Headlights/Other Vehicles"

Be sure and get the correct ones. 97-00 and 00-04 are different (00 can go either way).

Oldvetter

There are 2 brass gears available.

Rodney Dickman makes a duplicate of the plastic gear in brass, he furnishes all material needed, including: epoxy, new rubber bumper, lubricant, and a 3-legged brace for later year C5s.

BFranker makes an all brass gear.

Tyler valo

So 2000's can have either one, or can use both?

schmaltzr

A couple of suggestions from someome who has done this. I got Rodney's brass gear before he had the rubber bumper etc. It was a great setup and I'm very happy I did it. Don't rush the epoxy. Clamp the case if you use the epoxy. I think the 97-99 use screws to put the halves back together, but I'm not sure. My 00 used the epoxy. I clamped the case for a day before I installed them. I cleaned the case with brake cleaner to make sure there wasn't any grease residue to prevent the glue from holding. On the drivers side there are a bunch of washers used as shims between the gear casing and where it is mounted on the car. I found the washers to be annoying to install because they kept falling off. Instead of re-installing the washers, I replaced the washers with one nut. The one nut was the same thickness as the washers that were on there originally but it never comes off and makes it easier to install the assembly.

jdmvette

yeah man don't replace one POS broken gear with another that will do the same thing! get the brass one.

'VETTE PHASE

Early 2000s used the aluminum bolt together style, later 2000s used the plastic style that has to be epoxied. Always check to see what you have no matter what year, because the motor could have been replace by a previous owner.

sneakelman

The motor casing may be different, but the gears are the same. Get the Brent Franker gear. It eliminates the rubber shock absorber that can also go bad, thus making it a truly permanent fix.

MadMaxZ06

schmaltzr

I thought my 2000 had a build date of early January, would that be considered later in the year (build year)? - Ron

schmaltzr

I went to Brent Franker website, but I couldn't find anything about headlight gears on it. Is is on another site? - Ron

lytspeed1

After doin the gear thing twice with my 03 c5...I just finally went out and (gulp) bought a new headlight motor.....

'VETTE PHASE

I would look just to be sure. ....and look at both of them.

97-00 on the left 00-04 on the right

jdmvette

check this page:

http://www.bfranker.badz28.com/headlightfix/index.htm

Secret237

But I like the idea of a rubber bumper so that's why I will go with Rodney's gears as opposed to an all metal gear.

It's the gear teeth that strip, not so much the bumper.

atsugidad

In addition to replacing the gear, check that the motor itself is tightly mounted. The motor on my 02 is held in place by some bendable tabs. The motor gets loose with wear/age allowing the motor to move and the small gear on the motor to become partially separated / unmeshed from the large gear. This causes the gear to strip (especially the stock nylon one). Tighten the Motor Tabs using pliers or Hammer and punch.

Phil

Skinny Kid

My driver's side gear went out 2 weeks after buying the car. I went with Rodney's kit for both sides and I have had no problem's since. Rodney's kit is very complete and easy to install. I would recommend doing both motors at the same time so you never have to worry about it again.

Justin

schmaltzr

tricep

This was posted a while back. It is the exact same thing I did. It worked. It may be too late for you since you have already picked up the new gears and tore the housing apart.

Quote:here is an easier fix for this problem that doesnt involve taking the motor off at all. Just undo the linkage from the motor, and turn the motor manually until it spins the shaft 180 degrees, and put the linkage back on. Ive taken these out before, and the gears only go aroung about 90 degrees, so the other side of the gear is still like new.

Check on the headlight posts in this forum, it covers all of these issues.