2003 ZO6 Headlight Issues

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Feb 23, 2026 | 08:07 PM

CRVETTE92

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From: SAN DIEGO CA

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.

Feb 23, 2026 | 08:22 PM

Pounder

1/4 mile/AutoX

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From: Buffalo Texas

gears or bumpers worn out ???

Feb 23, 2026 | 08:51 PM

hyperv6

Melting Slicks

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From: North Coast

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.

Feb 24, 2026 | 08:48 PM

Vetteman Jack

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Apr 24, 2026 | 01:21 AM

CRVETTE92

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From: SAN DIEGO CA

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?

Apr 24, 2026 | 09:10 AM

mmartinez

Melting Slicks

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From: Espanola New Mexico

Most likely the plastic gears are stripped.

Apr 24, 2026 | 09:02 PM

CRVETTE92

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From: SAN DIEGO CA

Probably. I got some brass gears I'm putting in this weekend.

May 23, 2026 | 09:26 PM

CRVETTE92

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From: SAN DIEGO CA

I replaced the gears but still having the popping up issues. Any other suggestions?

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May 23, 2026 | 10:00 PM

LegionnaireCM

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From: Central Texas

Sounds like the motor housing cover could be flexing and unlatching. If the motor casing is tight, not flexing, possibly a headlight control module.

May 24, 2026 | 01:33 AM

#10

CRVETTE92

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From: SAN DIEGO CA

What would you suggest if indeed the cover is flexing? JB Weld it close?

May 24, 2026 | 04:59 PM

#11

LegionnaireCM

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From: Central Texas

Quote:

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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