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When I got home, last night, I shut the headlights off. When I did, the right one shut like it was supposed to, but the left one shut, then came back up half way. It did this about four times before I gave up. I then recalled that on Friday night, the right one hadn't wanted to come up when I turned them on. I manually raised it, but when I got home, it worked perfectly fine, as it did last night. I replaced both the headlight motor gears about two months ago. ('02 coupe).
I would check the plastic stoppers or "insulators" first. The white little end caps that cause the headlight arms to stop in place get cracked and worn out. This cuases the arms to function incorrectly. This takes about two minutes to check and if they are crack you can flip them over and they will work again. Naturally this is only going to work for a short while until they break off completely, but this may buy you some time until you can get to the dealership or order them online to replace them.
I just did this and it worked like a charm. No need to go through the whole "shimming process". The stoppers that were cracked on mine were the ones that were under the headlamp. Turn your headlamps on, then unplug the power connector to the headlight motor. The shroud had to me removed with a phillips head. Its just held on with 3 bolts. Access the plastic stopper and wiggle it off. Check it for cracks on the bottom side. If its cracked just flip it over and replug the power connector. See if that works before you go putting the Frankenstein shroud fix in place.
Hopefully that's your issue as well. If not, move on the shim fix. If that doesnt work it may be the headlight motor.
Johnny, haven't you figured it out yet??? The reason the plastic tips get broken is because the arm contacts the stops too close to the end. Solution--SHIM IT!!!!!!!!!!!!