1994 Headlight doors

[Packrat33]

Question:

1994 Head light doors.
When the doors open and when they close the right side door motor continues to run for a few seconds (2 or 3) trying to close the door and or open it.
Bad motor or some sort of adjustments needed.

Thanks
Paul

 

[Ken]

Sounds like the gears may be wearing out, which is not an uncommon occurence. The replacement gears are available through any of the aftermarket suppliers, such as Mid America Designs.

One caveat I was warned of, and that is to replace the plastic (?) gears in kind rather than use the optional bronze replacement gears. The thinking behind that (I believe) is mainly that eastern climates are harder on the equipment, and if snow or ice for example, was built-up on the headlamp doors, the stronger gear could possibly damage the door's motor, whereas the plastic gears would give a little. But I could be wrong, it wouldn't be the first time.

One other thing you might want to check and that is the manual override knob - is it secure? That is, is it clipped in the "hold" position?

 

[Tuna]

There are 3 half inch by half inch plastic gromets in the headlight motor gearing that provide the connection between the motor and the gear. They have turned to mush - or plastic sand actually. They are no longer providing the positive connection between the gears and the headlight. I've replaced them on both sides of my 92 already.

You can get the replace gromets from Mid-America for about 5 bucks plus shipping. Much cheaper than the gears - which are usually okay and much, much cheaper than replacing the whole motor/gear assembly.

I just replaced my drivers side last night. It helps to have the service manual and the instructions that come with the gromets.

 

[Packrat33]

I did not say in my post that the headlight doors don't open and close completely they do. They do not open only half way or anything lke that.
Dose this change any of the responses to this post.

 

[phrogs]

While your doors may be opening and closing all the way for now, the plastic bushings in the motor/ gear housing are starting to disintergrate that is why your motor keeps running, they cost about 5 bucks a side from the big part guys.
I changed them on my ZR1 I also put in the brass gear, its nothing you cant do in a afternoon just be sure to alight your headlights after wards..
If you dont fix it, soon not right away but in the future your headlights will start to droop and not open or close all the way..
If you want pull your headlight out then remove the side cover on the motor and you will see the bushings are probaly all broken up..

Its a cheap fix something you might want to look at doing.

 

[8388]

Are both sides doing it at the exact same time ? There is a headlight module that controls the headlights, located under the driver side headlight behind the nose. But they rarely go out. Make sure your electrical connections are tight, and no water/moisture has gotten to it.

If this is not it.then it's either the gears or the bushings.

 

[Packrat33]

Thanks to all that replied to my Q. I ordered and received the bushings and have just finished installing them. First one 1 hour 25 min and the second 48 min. They now work just great, again thank you all.

 

[onedef92]

I'll lay odds its your bushings. Go to Home Depot and ask for item number 595609. You will need six of these nylon spacers to repair both headlights. They cost me .69 cents (plus tax) for a pack of three at my local Home Depot store.

Much cheaper than the $7.99 price in MAD, Eckler's and some of the other specialty catalogs and they are the exact same Delrin spacers. Go figure.

If there's a TechTips portal on this Forum search under "headlight bushings." If not, let me know and I'll see if I can get you a copy of the instructions I used when I replaced mine a couple of months ago.