I have a couple of issues: 1: How do you adjust the headlight buckets ti properly align with the hood/quarter panel. 2: My driver side headlight won't open at times, but if I operate the motor manually, just slightly, it will work for a few revolutions, but then sticks again. Any suggestions on what might be the issue?

 

 

Moved to C5 Tech.

 

All C5s are not the same. Please update our profile with MY, Model

 

headlights sound like the plastic gear is stripping out

 

There are screws that hold the top finished part to the housing. Loosen the screws and align top and retighten. Your other issue could be worn stop bumpers that tell the motor where to stop. If worn too badly, it will cause the bucket to stay up or stay down. Raise your lights manually and remove the bezel. There is a small white-ish plastic bumper on the inside shaped like a D. A little metal arm strikes it when the lights are turned off telling the motor when to shut off. If this part is worn, the motor will spin too far and manually needs to be turned back to get it going again. Good news is that you can just pull this bumper off by hand and flip it over so the other (hopefully) non-worn side is being struck. There are also two identical bumpers on the back of the housing that don't get worn as much and can be swapped with the one on the inside as well. You can also buy new bumpers for about $10 a pair from Corvette Central and others. If you reuse your original bumpers and they seem loose, you can put a small piece of tape over the tabs they mount on and that will snug up the fit. I did this with mine and haven't had a problem since. Also, lube all the moving parts while in there.

 

Skooter, Thank you for the information!

 

You're welcome. I had the same issues with mine. I hope worn bumper is all it is. Easy and free to try anyway. 🙂