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2003 ZO6 Headlight Issues

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Old Feb 23, 2026 | 08:07 PM
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Default 2003 ZO6 Headlight Issues
My headlights pop up at random alot, even when they are off. Usually I need to talk on them or open the hood and drop it for them to go down. Any input on the possible issue? By the way I already cleaned the grounds associated with the headlights.
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Old Feb 23, 2026 | 08:22 PM
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gears or bumpers worn out ???
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Old Feb 23, 2026 | 08:51 PM
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Yes check the bumpers. One I likely worn if out of place.

you can move one from the back to the worn one till you get replacements.

Rodneydicman.com is the best replacement.
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Old Feb 24, 2026 | 08:48 PM
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^

And moved to C5 Tech.
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Old Apr 24, 2026 | 01:21 AM
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Bumpers are fine but still having the popping up randomly issues. Also, the head light motors still spin after the actuation is done. Could it be a bad headlight module?
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Old Apr 24, 2026 | 09:10 AM
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Most likely the plastic gears are stripped.
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Old Apr 24, 2026 | 09:02 PM
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Probably. I got some brass gears I'm putting in this weekend.
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Old May 23, 2026 | 09:26 PM
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I replaced the gears but still having the popping up issues. Any other suggestions?
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Sounds like the motor housing cover could be flexing and unlatching. If the motor casing is tight, not flexing, possibly a headlight control module.
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Old Yesterday | 01:33 AM
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What would you suggest if indeed the cover is flexing? JB Weld it close?
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Old Yesterday | 04:59 PM
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Originally Posted by CRVETTE92
What would you suggest if indeed the cover is flexing? JB Weld it close?
If it's flexing or splitting under load, it needs to be heavily clamped and re-glued with structural epoxy, braced with a reinforcement T-bracket kit, or the motor assembly might have to be replaced. My neighbor’s C5 is doing this, currently. It’s not uncommon from what he’s saying.
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