Headlight Gears/Motors

[Rob]

So, I'm starting to develop problems with my headlights hesitating while opening and closing. The driver's side motor runs about 6-8 seconds longer after the headlight has closed.

I'm assuming it's the crappy plastic gears that were used.

What is the best solution to fix these?

How difficult is the job and are there any specific tools I'll need?

 

[Rob]

Reposted from the ZR-1 forum...

 

[boomdriver]

what yr is the car in question?

pre-88 used gears while everything after that used the pin type transmission. If its the pins worn out the gears are likely fine. The pins are designed to absorb the wear. lessons learned from gears that wore out far too soon on earlier models.

Tools...? 10mm sockets/wrench for bracket assy removal IIRC, philips for case screws, white grease, new pins/rods, dowels or whatever you want to call them (3) silicone and some patience.
Its not bad. Remove the gear box/motor and separate the case halves. The inside might be full of what WAS dowel pins...so clean as needed. Replace pins, lube, I like to use a thin layer of silicone on the case edges, reassemble and mount. Timing of the doors is thru the control module unlike the earlier models that used limit switches inside the motor.

 

[Rob]

1990

 

[boomdriver]

yep....should be the pin/dowel drive. There should be several threads there that describe in detail the in/outs of pin replacement. Because its a $2 fix (if that much) and shops will nail ya for $150...its a pretty popular subject.

Thats why older cars with gears are strongly advised to upgrade to the pin type motors...gears will always cost $50 or more per set. Pins cost pennies if you make them out of various materials that are available from the hardware store.

 

[roger longman]

Hi Rob, Yes, Boom is right. The first one I did was a bit of a pest but, the next much easier. I then did a couple, for the heck of it and finally one I found from a Jap car. From Autozone you can get the bushes for Ford windows or Home Depot, I understand, has the dowels for pennies......Roger.

 

[TedC]

Similar issue on my 1989, except it was the passenger side. I picked up the right parts from one of the vette catalogs. Gears were in perfect shape. The replacement parts came with instructions. This is not a 30 minute project. Plan on 2 hours per side. Not difficult, just time consuming. I found one side harder than the other due to the design. Also, one of the gear seals was not installed right from GM, so I made a custom replacement gasket. If you search the net, you can find a replacement kit that also includes new gaskets for a little more money. The three "bushings" per side fall apart with age. Do both sides while you have all the right tools out.

 

[roger longman]

Hi Rob, From memory, tools required are : 10mm ring/open-ended wrench, smaller 6/7 mm open-ended,screwdriver and, I used, 2 paper clips, bent to suit, for holding the bushes apart during reassembly......Roger.

 

[Dad]

A bit old school, (pictures are black and white), but if you can get past that it should be easy. Make Your C4 See Well

 

[roger longman]

I did mine, without the help of any instruction, by going in from the top and withdrawing the shaft through the motor. I shall have to look out the spare and try both ways. I also made the spare dowels out of something I found laying about, having bought the first sets from the Corvette dealer. I seem to remember they were all solid and as said, pennies from Home Depot......Roger.