Replacing Headlight Motor Gear and Bushings
Thread Starter
Heel & Toe
Joined: Nov 2020
Posts: 20
Likes: 0
Replacing Headlight Motor Gear and Bushings
Hi Everyone, I have a 1996 C4 and in the process of replacing the gear and bushings on the passenger side headlight motor. The bushings have disintegrated hence the motor will not shut off. The problem I ran into is upon removing the motor from the headlight assembly and opening up the housing to get to the gear, I can't get the gear out of the housing. The gear is on the stem and moves freely but is stuck in the housing for some reason. I watched a video and the guy said to put a screw driver thru the hole on the stem and pull. I did but it won't pop loose. Note: On the drivers side there is an opening on the housing to get a screw driver in and push the gear/stem out using a hammer. The passenger side doesn't have this design. Any suggestions on how to remove the gear that is on the stem out of the motor housing? Thanks.
Racer
Joined: Jan 2022
Posts: 257
Likes: 114
Mine was stuck also. I opened up my vice and put the gear on top (not in the jaws) and used a metal pin punch and gave it a few smack with a hammer. It popped free. Might want to spray a little WD-40 in there also.
I'd also suggest replacing with a brass gear set instead of plastic. You don't want to do this again. Good luck.
I'd also suggest replacing with a brass gear set instead of plastic. You don't want to do this again. Good luck.
