Driver's Side Headlight - Won't Pop Open ( odd symptoms?)
Thread Starter
Burning Brakes
Joined: Aug 2007
Posts: 831
Likes: 2
From: Houston Texas
Driver's Side Headlight - Won't Pop Open ( odd symptoms?)
OK, I have read the posts concerning the broken nylon headlight gears for the C5 headlights ( common issue). I bought the bronze gear repair kit, which I can install when needed.
My driver's side headlight has been randomly failing to pop open. In the past, all I had to do was cycle the on / off switch a couple of times and it would operate. It's only on the opening cycle that there's an issue, once opened it always closes. However, last night the headlight would not open ( or pop up) no matter how many times I cycled the switch. I did not hear any noises or clicking/grinding sounds from the motor, the headlight lamp turned on.
Today, I removed the rubber boor covering the manual **** and twisted the **** a little back and forth. Lo and behold, the head light now seems to operate fine again.
Any thoughts as to what is going on? Why by turning the manual **** does does the headlight mechanism seem to work fine (electrically)? If the nylon gear is shot, wouldn't I be hearing some noise or clicking sounds from the motor when it fails to open? When mine does not open, I hear nothing.
My driver's side headlight has been randomly failing to pop open. In the past, all I had to do was cycle the on / off switch a couple of times and it would operate. It's only on the opening cycle that there's an issue, once opened it always closes. However, last night the headlight would not open ( or pop up) no matter how many times I cycled the switch. I did not hear any noises or clicking/grinding sounds from the motor, the headlight lamp turned on.
Today, I removed the rubber boor covering the manual **** and twisted the **** a little back and forth. Lo and behold, the head light now seems to operate fine again.
Any thoughts as to what is going on? Why by turning the manual **** does does the headlight mechanism seem to work fine (electrically)? If the nylon gear is shot, wouldn't I be hearing some noise or clicking sounds from the motor when it fails to open? When mine does not open, I hear nothing.
Last edited by NatB; Aug 3, 2014 at 06:32 PM.
Le Mans Master
Joined: Apr 2012
Posts: 7,832
Likes: 2,274
From: Brighton MI
Had this happen to me only once...Woodward Dream Cruise last year, when I also experienced the "wait 10 seconds..." inconvenience several times. I attributed all of this weird electrical gremlin stuff to heat soak due to the long hours of idling around.
Burning Brakes
Joined: Apr 2007
Posts: 966
Likes: 9
From: Phoenix AZ
I replaced my nylon gears with brass awhile back and recently was having the same issue you describe. The headlight would intermittently not pop up and when I twisted the motor **** a few turns it would raise normally. Turns out that the rubber bushing that fits inside the gear was damaged which was causing things to bind up. I replaced the bushing and now everything works normally.
I bet you'll find something similar when you R&R your gears.
I bet you'll find something similar when you R&R your gears.
Thread Starter
Burning Brakes
Joined: Aug 2007
Posts: 831
Likes: 2
From: Houston Texas
I replaced my nylon gears with brass awhile back and recently was having the same issue you describe. The headlight would intermittently not pop up and when I twisted the motor **** a few turns it would raise normally. Turns out that the rubber bushing that fits inside the gear was damaged which was causing things to bind up. I replaced the bushing and now everything works normally.
I bet you'll find something similar when you R&R your gears.
I bet you'll find something similar when you R&R your gears.
I will just need to make the time soon to do the repair.
Advanced
Joined: Jul 2012
Posts: 66
Likes: 0
From: goodman mo
I would check the nylon stops. I wish I had a pic for you.
They get wore down and over extend the linkage. Next time it wont pop up give the manual **** a couple turns, if it pops up that is your problem.
Take the nylon stops off and flip them around.
The nylon gears can also be turned 180 degrees( just one time)
Do a search for the stops, it is an easy fix.
They get wore down and over extend the linkage. Next time it wont pop up give the manual **** a couple turns, if it pops up that is your problem.
Take the nylon stops off and flip them around.
The nylon gears can also be turned 180 degrees( just one time)
Do a search for the stops, it is an easy fix.
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Instructor
Joined: Feb 2004
Posts: 169
Likes: 3
From: The Villages FL
I had the same problem....intermittent left headlight....no noise....next day/night it'd work....went on for weeks....was gonna change the gear but thought I gotta remove the motor anyway so I just ordered a rebuilt motor thru Parts Geek....great video on here on replacing the gear if you elect to do so....At least when I turn the lights on manually they work.
