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This morning I drive my 2002 Z06 to work; I leave early in the morning so I have to use my headlights. They go up without any issue; no delay, no weird noises; all seems normal. I stop at a convenience store on the way and turn the lights off; go into the store and when I come out I notice the driver's side headlight is still partial up. (WTF?)
Start the car up, turn the lights on and the driver's side goes up and then down; passenger side stays up like it should. Turn them off and the passenger side goes down but, the driver's side goes up; not all the way but, up.
I tried using the manual **** to raise the headlight door but, when I was turning it the headlight didn't want to raise up and, if I lifted the door manually there was a lot of slop. Finally got the door to open all the way using the **** but, as soon as I turned the lights on, it closed.
I have already replaced the plastic gears with the brass ones and the doors worked fine for years until this morning. Do I need to replace the motor now?
Friend found a You Tube video showing a fellow C5 owner who had the same issue. Turns out that the 10mm nut which connects the actuator arm to the headlight door had come loose and one of the stops had become damaged. Tightened the nut, swapped out two of the stops and we're all working fine again. You Tube is a life saver (and money saver).