Headlight malfunction on an 04

[nightster]

Well the other night I turn my headlights off, they both close like normal, passenger starts closing followed by the driver side half a sec later. Then after both are closed the driver side opens half way back up. I turn them back on it closes then reopens with passenger side. When I turn them back off it does it again. Any ideas on how to fix this? Here's a picture of it in the half open position. If I turn the lights off and hold it down it stays down, that way I don't drive around "winking" at everyone.

 

[Toms007]

My initial thought would be the nylon gear is worn and causing this. It's a common issue with the C5, but can be repaired better than new with the replacement with a brass gear.

I'll search and see if I can come up with a thread that addresses the problem.

 

[Toms007]

Here's another possibility....

http://www.corvetteactioncenter.com/forums/c5-general-discussion/126459-headlight-insulators.html

 

[nightster]

Thank you very much

 

[Toms007]

Here's a write up on gear replacement

http://www.corvetteactioncenter.com/forums/c5-general-discussion/108600-2000-headlight-motor.html

 

[catbert]

This is always my first step - crank the light all the way up, then all the way down with the lights off. It's actually worked for me. It's free, and takes a couple minutes - what have you got to lose?

 

[nightster]

I actually went out in the parking lot and fixed it on my lunch break lol. After doing a lil googling I found out there are plastic peices on the tabs that stop the light when turned on and off. The lights have been used so much that the plastic peice had been worn through. I simply pulled the peice off flipped it over and put it back on. Works like a champ now. Ill post some pictures later if I get time. Thanks for the info...

 

[Junkman2008]

Yep, this is the old "bump stop" problem. There was a guy on another forum who did Corvette restorations. He had a whole bag of those things and was giving them away to who ever wanted some. I grabbed 4 just in case I ever needed some. Here's what they look like.

There are 4 bump stops per headlight. Two that would be in that picture and two at the back of the headlight where it touches the top of the inner fender when the headlight is raised. (viewable with the hood raised).