Its been a long frustrating battle with my drivers side headlite motor. Its the typical stripped plastic screw gear which I replaced 2-3 yrs ago. Then the epoxy glue cracked and broke on the housing that holds the gearbox together...couple of times...I forget how many times I fixed it, put back together and even taped it with electrical tape (added insurance). Then I also applied the small washer on the motor hub as recommeded by a Chevy Service Bulletin, think this moves the lever just a little to keep from chewing up the stopper.

But the lever that is connected to the motor hub still keeps chewing up small dirty yellow hard plastic stopper (right at the smooth edge of the stopper)....have brought about 10 of these suckers at about $6 a piece, and chewed up the back of my hand too many times to count to do the unstall and reinstall. Tried some of this new fagled epoxy glue (PC-7) on the chewed up stoppers (since it was only $7), to see if I could re-use some of the chewed stoppers....No luck ...1-2 times on the headlite motor and they are poop.

Still the same problem...chews up the stopper...any ideas or help out there? Similiar experience...Too frustrated to do a search ...if someone knows if there is new info out there that can be searched...please advise I will search otherwise any other new ideas.
Thanks

 

There are 2 gears available: BFranker and Rodney Dickman.

BFrankers gears are solid aluminum with no rubber.

Rodney Dickman has a "new" metal bracket for holding cases closed, you can buy it by its self.

Suggest you try the metal bracket.

 

You might try Rodney Dickman....He has been selling upgrade parts for the pop headlights longer than anyone I know of...same parts were used on the old Fiero mid engine, so the problems were discovered and solved in the aftermarket a long time ago. From what I have seen, GM never figured out how to make them durable, or reliable. He may well have a specific fix for what ails your headlight motors...

http://www.rodneydickman.com/n113.html

A lot of C5 Corvetteforum people have used his parts over the years, and sooner or later I will too....I have the all glass Eurospec T-84 headlamp modules that are quite a bit heavier than the stock plastic crappers...One of these days I will have a stripped gear....just a matter of time.

Good Luck!

EDIT.....
JUST SAW THAT OLD VETTER POSTED WHILE I WAS STILL WRITING , SO