Recently I have started having an issue with the driver side headlight. It wont open unless i loosen the manual **** on the motor so it seems like its over tightening itself. I replaced the gear a few years ago so I'm not sure why the issue suddenly started. If anyone has had a similar issue I appreciate any info.

Thanks,
Brian

 

If manually relieving the pressure allows it to work and the motor works fine closing, while not producing the well known "rat-rat-tat" noise, chances are your motor is OK and it is just the bump stops that limit the closing action what needs to be replaced (even though they might look fine to the naked eye). The ones that limit the opening action are probably fine, but I would replace all 4.

The way the headlights work is not based on predetermined positions. When the headlight doors open or close and they reach the end of their travel, they press against the corresponding rubber bump stops. As a result the current through the headlight motors increases and that is sensed by the Headlight Door Control Module, which in turns cuts power to the motors.

If there are missing or damaged bump stops, or they are scored too deep, the motor might keep working longer than really needed, which could result in over torque. If that happens, the next time the motor is operated it would require more torque to perform the action. That would mean more current than normal and the possible intervention of the Headlight Control Module, shutting again the motor before the door actually moves.

If you need replacements you can order them from here.

In addition to that, there is a TSB for the driver's side headlight motor that calls for shimming it.

 

Moved to C5 Tech.

 

I have this exact same problem, its been happening for a while now. It's really bugging me but I haven't gotten around to fixing it. I've already installed Rodney Dickman's bump stops but that hasn't fixed it, so i'm going to try shimming the motor and see if that helps. I also installed the metal gear. I don't think it is the motor because when you loosen the **** the motor works fine for a little while, then tightens up again. I have never had any problems with the right side motor.

 

Have you checked how tightly secure are the bent retaining tabs that hold the motor to the gear case? It's possible they got loose when the gear was replaced.

If these tabs are too loose, the motor can move in relation to the gear case. This could create slop in the gear-to-worm engagement, causing premature gear failure due to wear, and perhaps also allowing the over torque that's occurring at the end of the closing travel.

The tabs can be bent inward a bit by holding the motor on a vise and tapping the tabs in with a hammer and screwdriver or similar tool, until the motor is tightly secured to the gear case.

 

I'll check that out when I remove the assembly from my car. I'd like to fix this before I install the ACA headlights I have.

 

I have a similar problem.
When I'm driving and I try to turn on my lights the doors will not open. When I get home, stop and try and turn on the lights all is great, doors open lights come on?

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