Headlight bushing - trying to understand the design

[TedC]

I'm in the process of replacing the headlight bushings on my 1989 Corvette. Looks like a common issue on C4s due to age. The 3 bushing on the right side turned to dust, and 2 of the 3 bushings on the left side had cracks and are ready to split. When looking at the parts, I'm still trying to understand why GM designed the gears using these bushings. Is this some type of clutch to protect the motors if the headlights can't spin? Must be done for a reason that I don't fully understand.:W

 

[BigJimZ16]

The same basic design is used in industrial couplings, the idea is to spread the load out onto more surface area hence making the coupling more dependable. I would assume that similar thought went into the headlight design for safety purposes.

 

[TedC]

Interesting. It looks like a design that is a little more complex than required. After installing the new bushing, it was apparent this setup was not some type of clutch, but a way to connect the large worm gear to the shaft. Three bearings per side lock the two together. The new bushings are in and both headlights open and close just like new. Not a difficult job, but it was time consuming. The vette is ready now for NYS inspection.

 

[BigJimZ16]

Good job... now go drive it like you stole it!!!