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C5 Headlight issues

XLR8

Gone but not forgotten
Joined
Jun 23, 2004
Messages
6,662
Location
Mississippi Gulf Coast
Corvette
2003 AE Convertible, 1998 LCRM Convertible
This morning when I arrived at work and turned off my headlights, the lights went off and lowered immediately, but I heard a grinding (ratchet-type) noise for several seconds, then it stopped. It sounded as though it may be coming from the passenger side light.

Then... when I was driving home this evening, I discovered that the lights flip up (staying off) when I turn on my parking lights. Tried it several times and it happened each time I turned on "Parking Lights"... lights flip up but stay off until I turn on "Headlights". ;shrug

:wJane Ann
 
Jane Ann, not sure about the flipping up part, but the grinding is most likely the good ole gear going out!! Anyone owning a C5 for any period of time will experience that dreaded sound! :W As you may already know, replace with metal and possibly replace both at the same time to avoid doing the second one later.
 
I'm afraid you're correct, lefty. I suspected a gear going bad as there are lots of related threads in the C5 forums, but the headlight pop-up when the PL are turned on has me mystified. I was only able to find one related thread and there weren't any replies to it.
 
HI there,
As far as the lights poping UP after shutoff, those bumpers may be worn on the actual bracket itself.

They are white in color and if there is any appreciable wear, they will cause your condition.

Allthebest, c4c5
 
Hi Paul! Thanks for the info. I was going to send you a PM if I didn't hear from you by next week. I'll probably take her to Kevin Tuesday.

If all goes well, I'll try to post a thread with pix after the fix.
:wJane Ann
 
I had the same issue a few months back. I turned the lights off both buckets go down and the right one pops right back up. The bump stop was warn and almost falling off. I popped it off put a small amount of epoxy in the slot flipped it over (so the good side was being used to stop the bucket) and pushed it back on. Its worked great ever since. It took me longer to find and mix the epoxy than to fix the bump stop.
 
Continuing on............

Update: and bear with me... I'm no mechanic and relating all this secondhand...

The problem isn't popping up after they're turned off. When I turn the headlights off, they go down - and stay down - but make the staccato sound for several more seconds, then stop.

When I turn on my Parking Lights or Running Lights, the headlights flip up, but the lights themselves don't come on. They just flip up, which they've never done with the Running Lights turned on.

Initially, we looked at the headlight motor: passenger side is the one which keeps running for several seconds, as though a limit switch isn't being made or a signal isn't being sent. And the headlight control/turn signal switch as the source causing the lights to pop up when they are supposed to stay down.

Kevin and Sandy looked at several wiring diagrams and schematics, by the way, while troubleshooting the issue.

The first thing they did was replace the turn signal stalk/switch. The thinking was that let's stop the lights from flipping up unwanted before replacing the headlight motor so as not to strip the gears on the new one.

Problem is, that didn't stop the flip up when turning on the Running Lights.

They replaced the new turn signal switch with the old one and started back on the wiring diagrams. Finally, they came across a diagram that shows a headlight module located BENEATH the headlight.

On my way back to the shop yesterday, my turn signals wouldn't work. So we replaced the TS switch with the new one and they worked fine.

Sandy spent the day on his back under the dash up to his elbows in wiring, testing and following and tracing wires.

The issue, as I understand it, is there is no COMMONALITY between the two issues. No problem that would cause BOTH issues together, that is, the headlights flipping up when the RL are turned on and the delay in the headlight motor shutting off.

Kevin mentioned that it could be as simple as two wires touching due to insulation cracked/missing/eaten by a rat etc. - OR - it could be something like a problem in the dash cluster, the only common link that the two DO share. I also reminded Kevin that about 4 months after I bought this Vette, we discovered the notorious "battery leaked on the wiring harness" issue.

So I'm driving the car as is while Sandy does some research for the next couple of days. Kevin will be out of pocket for a week or two because of a trip to the Mayo Clinic to undergo testing himself (my buddy Kev has been on the list for a liver transplant for quite sometime now).

The only good thing is, these guys will NOT throw expensive parts at the problem, emptying my bank account while taking wild-a$$ guesses. They've always treated me well and taken good care of my Corvette AND me.

Any suggestions or insights you C5 guys can offer would be appreciated and passed on to my pit crew.

:wJane Ann
 
Btw...

I checked the DIC to see if it's throwing any codes and there are only 2 - both H or history codes:

28 TCS - C1255 H ( EBTCM Internal Malfunction )

AO-LDCM - B2264 H ( Vertical Position Sensor Fault )
 
After researching across the web, I came across this post by a C5 owner:

My C5 did the same thing, the headlights came up with the parking lights when my one gear was stripped. All was fixed when I replaced the single bad headlight gear.

Apparently, it has to do with the headlight module operating in the "time override mode".

Normally the headlight module turns off the power when it finds a high current surge from the motors when the headlights hit their stops (either up or down) and the motors can't turn.

But this continual trying to turn at the stops, causes the plastic gear to strip, when this happens the motor can continue to turn (you may hear the machine gun noise) and their is no current surge.

There must be a "time override" built into the headlight module, and it turns off the power if a surge is not detected within a certain time period (like 5 seconds).

Well, when this "time override" feature is used enough, something gets "thrown off" and it can cause headlights to raise with just parking lights being turned on.

I called Kevin and talked it over with him. Unfortunately I'm out of time since I'm going back to work today. My next day off is Tuesday and we'll replace the headlight motor then. Hopefully this will fix the problem.

I'll post more then.
 
I am pretty sure that Kevin and Sandy are over thinking this issue. They need to start with fixing the noise issue (which is the hard problem), and is most likely stripped headlight gears. I would recommend to have them take the motor apart and inspect it.
 
I finally had time off again and took the car back to Kevin's shop.

We replaced the headlight motor, passenger side, then the driver side motor started doing the same thing. :eyerole... hey, the Vette's 12 years old and has 110,000+ miles on it so I guess it's time.

We replaced the driver side motor too. This has fixed both problems. The "machine-gun" noise is gone AND the headlights no longer pop up when the running lights (or parking lights) are turned on. :thumb
 

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