My left headlight housing will not open. The only way I can get it to open is to turn the manual open **** a few turns counter clockwise. Then when I turn on the headlights it opens normally, but that only lasts for a few openings and closings and then it won't open again. Any ideas?

 

It's very probable that you just need new bump stops.

If manually relieving the pressure allows it to work and the motor works fine closing, while not producing the well known "rat-tat-tat" noise, chances are your motor is OK and it is just the single bump stop that limit the closing action what needs to be replaced (even though it might look fine to the naked eye). The 3 that limit the opening action are probably fine, but I would replace all 4 (it might be a good idea to do the same to the other side as well).

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 stop(s). 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 (number 4 in diagram below) 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 (number 2 in diagram below).

 

Did you change your bulbs by chance to HID or LED setup?

 

The problem is opening, not closing, and it works after manually beginning to open it

 

True, but I encountered a similar issue when I changed to HID bulbs only one side would open and not both. As a short term solution I would have to close the lights again, then put my high beams on while opening and it would work. Once I added a resistor my problem went away. Not saying he has the same issue, and very well could be the bump stops, but thought I would cover all basis

 

What happened to you was very interesting. Glad everything is working fine now!

 

 

Moved to C5 Tech.

 

Evidently you've not experienced the damned light door problem... I have! and we would not have learned what the fix was without help I got here! Please be cognizant of that before the "editing out thing" that you like to do... Thanx

 

Thanks very much for the in depth explanation! I ordered 4 new bump stops from the company you sited. Two of the bump stops are visible on the drivers side assembly but I'll be damned if I can see two more anywhere on that assembly?

 

In each side there are 2 (1 for "open" and 1 for "close") directly limiting the sweep of the motor linkage (number 4 in diagram below):



And 2 more, to provide support to the headlight door in the "open" position:



If you only bought 4, I would suggest to replace the 4 that get the biggest beating: the two shown as number 4 in diagram above. Replace both sides

 

Thanks a lot for the advice on my headlight not opening. I ordered four new bump stops, installed them a voila problem solved.

 

Glad to be of service!