C4 headlight problem

[whytryc4]

I have a problem with headlights on my 91 Corvette. When I turn the switch on the headlights work but will not pop up and when I turn the switch off and on again they will pop up and work correctly.

 

[w8n4ya]

Hello whytryc4,

I recently experienced this headlight issue with my 1990 coupe. Here's what I did for a permanent fix:

"Inside the 1988-96 headlamp motors is a gear which turns the lamps. From the factory, the gear is packed with a special hard gel that turns the gear. As time passes, the gel deteriorates and no longer has the strength to turn the gear so it free wheels." - Eckler's

Both catalogs, Eckler's (p/n #29304) & Mid America Motorworks (p/n # 601-703) sell replacement Delrin Bushings for $4.99 a set. You will need two sets if both headlights exhibit the same symptoms. The fix is very easy. I was able to find photographed instructions on this website:

http://www.corvettemagazine.com/2002/february/c4lights/light1.ASP

Also, www.corvettedoctor.com has a similar documented fix in the technical section. I found both articles very helpful when doing my repair. Good luck to you, I hope you found this infomation helpful.

 

[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.

 

[whytryc4]

Thanks for the help, but for some reason the headlights have not failed any more, also as i live in Australia we dont have the luxury of having parts availiable at the stores you have suggested.

 

[onedef92]

Thanks for the help, but for some reason the headlights have not failed any more, also as i live in Australia we dont have the luxury of having parts availiable at the stores you have suggested.

At .69 cents for a package of three, I don't think a true-blue Corvette enthusiast would balk at shipping them to you.