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My right (passenger side) headlight is not popping up -again! I had this same problem in June and my mechanic replaced the headlight motor assembly ($199 labor plus $424 part). Someone told me that it probably was a broken plastic gear that could easily be replaced. Could this be the likely cause and inexpensive solution? Any suggestions?
You received good advice in the previous post. Let me just add some links so you could have more info on hand.
There are several kits available to replace these plastic gears, but this one is one of the best (pay attention because there are 2 different kits: one for "97 to early 2000" and another for "late 2000 to 2004"). Read these step-by-step directions to understand what's involved. If you have to replace the gears and you decide to go the DIY route, you could save money and they will last forever
You might need these as well (the rubber bump stops).
There is a TSB, that calls for shimming the driver's side motor. The parts needed for this are included in the above mentioned kit.
Of course you have given us NO information about the car like YEAR!!!!
Headlight motors are not the same for all years. 97 - 99 were screwed together making access to the gears easy. 2000 - 2004 were glued together making access to the gears more difficult but still doable.
Are you hearing grinding noises when you try to open the headlights? Have you tried using the manual **** to raise the headlight??
Have you checked the basics like is the fuse for the right hand side motor good? Fuse #3 in the engine compartment fuse box.
Could also be a failed headlight control module.
Thank you for your response. Sorry that I didn't give you sufficient information - I'm new at this!
My car is 2003 convertible with manual trans. I was looking for possibly a simple, cheap fix (not another $600+ repair). Apparently it might not be that simple and therefore I would rather have my mechanic do it - with giving him the suggestions from you and the other respondents.
With that being said, I did try to check a few things. There is no grinding sound. I did try the manual ****, but I didn't know exactly what to do. I did find the manual **** and it said to remove the rubber cover. It wasn't obvious to me what to do after that-I didn't see anything I could turn. Fuse #3 seamed to be OK.
Although I'd like my mechanic to fix this, I'll also like not to pay a $600+ repair for this fix every 5 months! Any other suggestions?
You received good advice in the previous post. Let me just add some links so you could have more info on hand.
There are several kits available to replace these plastic gears, but this one is one of the best (pay attention because there are 2 different kits: one for "97 to early 2000" and another for "late 2000 to 2004"). Read these step-by-step directions to understand what's involved. If you have to replace the gears and you decide to go the DIY route, you could save money and they will last forever
You might need these as well (the rubber bump stops).
There is a TSB, that calls for shimming the driver's side motor. The parts needed for this are included in the above mentioned kit.
Thank you for your suggestions.
If it is the gears, and since I am not a big do-it-yourself'er, do you think that I suggest to my mechanic that he replace the gearing with gears from these kits? In other words, do you think that the gears in the kit would last longer that the ones that come with the complete Headlight Motor Assembly that he replaced in June?
Thank you for your response.
How would I know if the problem is "bumper stops"? Sorry but I don't know what to look for if they were the problem, and even where they are, or how many bumper stops there are.
Don't throw money at this. I really doubt the gears would go bad in a few months if he replaced with new and you heard no gear noise.
If you can turn the **** and raise the HL some and then turn the HLs ON and it goes up it is probably the bumper stops. Takes a lot of turns to make it move some.
Try that and let us know. If it does not go up then the motor may not be getting power for some reason we can figure out.
If this gets complicated I would be glad to walk your mechanic thru the diagnostics.
...gears in the kit would last longer that the ones that come with the complete Headlight Motor Assembly...
The kits have bronze gears, while replacement motors usually come with plastic gears like the factory ones. So, yes, they should last longer, although I would expect a plastic gear to last more than just a few months.
You seem to be having some problems finding the manual headlight *****. Here's a pic to assist. Counter clockwise to open. Clockwise to close. Takes a lot of turns to move the headlights a little. Sometimes headlights get stuck. Turn the **** on the offending headlight a little to "loosen" it then see if it will open normally with your switch. If not, then you might have an electrical gremlin to trace down. GL and keep us updated.
You seem to be having some problems finding the manual headlight *****. Here's a pic to assist. Counter clockwise to open. Clockwise to close. Takes a lot of turns to move the headlights a little. Sometimes headlights get stuck. Turn the **** on the offending headlight a little to "loosen" it then see if it will open normally with your switch. If not, then you might have an electrical gremlin to trace down. GL and keep us updated.
Thank you for your input and the picture. I did find the ****. It has a rubber cap. Do I remove this rubber cap and turn something under the cap or just turn the rubber cap itself?
Don't throw money at this. I really doubt the gears would go bad in a few months if he replaced with new and you heard no gear noise.
If you can turn the **** and raise the HL some and then turn the HLs ON and it goes up it is probably the bumper stops. Takes a lot of turns to make it move some.
Try that and let us know. If it does not go up then the motor may not be getting power for some reason we can figure out.
If this gets complicated I would be glad to walk your mechanic thru the diagnostics.
Mr. Sam
Thanks - I'll try turning the **** and see what happens.
Just turn the **** as shown in the picture. Good luck, we'll figure out the issue with as little money as possible.
My manual **** has rubber cover with the following message imprinted on it: "REMOVE FOR MANUAL OPERATION". I tried removing the cover but found no way to turn the ****. I put the cover back on and turned the rubber cover a few turns, counter clockwise. I raised the head light about 1/8 inch and tried the light. Both headlights popped up! I tried the lights on and off quite a few times and everything seams to be working fine.
I have no idea what happened. Why did it malfunctioned initially? Why is it apparently fixed now? I wonder if the initial problem was a simple bumper stop (whatever that is) that you mentioned earlier (and my mechanic replaced the whole headlight motor assembly to "fix" the problem)? Also why did the cover say to "REMOVE FOR MANUAL OPERATION", when the only apparent way to turn the **** is with the cover not removed? And finally, should I ask my mechanic to check anything out so this won't happen again?
Last edited by rpraught; Nov 16, 2015 at 10:49 PM.
These ol' headlights are giving you fits...heh. In post #8, dadaroo told you it was probably the bumper stops. Over time, the bumper stops get worn or worn out might be a better term. They're simply hard nylon/plastic stops that tell the headlight when to stop trying to open or close. If I remember correctly, there are 4 on each headlight. To see them you have to raise the headlights, then look below them. Two in front and two in back of each headlight. They simply slip on to a metal arm and they are reversible (you can take them off, turn them over and slip them back on). And what do these mysterious bumper stops look like? Here ya go...
Last edited by CactusCat; Nov 16, 2015 at 11:03 PM.
My manual **** has rubber cover with the following message imprinted on it: "REMOVE FOR MANUAL OPERATION". I tried removing the cover but found no way to turn the ****. I put the cover back on and turned the rubber cover a few turns, counter clockwise. I raised the head light about 1/8 inch and tried the light. Both headlights popped up! I tried the lights on and off quite a few times and everything seams to be working fine.
I have no idea what happened. Why did it malfunctioned initially? Why is it apparently fixed now? I wonder if the initial problem was a simple bumper stop (whatever that is) that you mentioned earlier (and my mechanic replaced the whole headlight motor assembly to "fix" the problem)? Also why did the cover say to "REMOVE FOR MANUAL OPERATION", when the only apparent way to turn the **** is with the cover not removed? And finally, should I ask my mechanic to check anything out so this won't happen again?
Trying to answer them as you asked them.
Why did it malfunction initally? Probably a worn bumper stop. The motor tightens down too hard and then doesn't have the strength to reopen. When you manually loosened it a little, worked just fine.
Why is it apparently fixed now? Probably just a one time glitch but if it happens again you know what to look for. One of my headlights has this happen occasionally. No problems. I just fix and move on.
"I wonder if the initial problem was a simple bumper stop?" Who knows, maybe. You should have asked here in CF before you took it to the mechanic. We like to do things as inexpensively as possible plus you get to learn about your car.
Lastly, the Remove for Manual Operation. I agree, its a little confusing but all of us told you to just turn the ****. No harm, no foul. You now know to ignore this. And the headlight saga comes to a close......
Last edited by CactusCat; Nov 17, 2015 at 01:00 AM.
These ol' headlights are giving you fits...heh. In post #8, dadaroo told you it was probably the bumper stops. Over time, the bumper stops get worn or worn out might be a better term. They're simply hard nylon/plastic stops that tell the headlight when to stop trying to open or close. If I remember correctly, there are 4 on each headlight. To see them you have to raise the headlights, then look below them. Two in front and two in back of each headlight. They simply slip on to a metal arm and they are reversible (you can take them off, turn them over and slip them back on). And what do these mysterious bumper stops look like? Here ya go...
Thank you for the very complete explanation and the picture - that was very helpful!
Trying to answer them as you asked them.
Why did it malfunction initally? Probably a worn bumper stop. The motor tightens down too hard and then doesn't have the strength to reopen. When you manually loosened it a little, worked just fine.
Why is it apparently fixed now? Probably just a one time glitch but if it happens again you know what to look for. One of my headlights has this happen occasionally. No problems. I just fix and move on.
"I wonder if the initial problem was a simple bumper stop?" Who knows, maybe. You should have asked here in CF before you took it to the mechanic. We like to do things as inexpensively as possible plus you get to learn about your car.
Lastly, the Remove for Manual Operation. I agree, its a little confusing but all of us told you to just turn the ****. No harm, no foul. You now know to ignore this. And the headlight saga comes to a close......
Thanks for answering all my questions-very much appreciated!
If the bump stops are still in place you will likely find that they have deep impressions where the pressure of the opening/closing stop has crushed the plastic. As explained by CactusCat you can pull them off and turn the uncrushed side around but if you do that I suggest that you use some form of adhesive to retain the bump stop. They are well known for falling off if not stuck back on with adhesive. I use RTV silicon.
Thanks for sharing this information.
I brought my car in to my mechanic today. I explained what you and the other guys had explained to me and he turned what stops he could to the uncrushed side and somehow made repairs to all bumper stops on both the left and right headlamps; using adhesive on everything. So I think that will solve my bumper stop problem for quite some time!
Again thank you and all the others who contributed - all very much appreciated!.
Headlight not popping up
