Help … the dreaded “Corvette Wink” and I can’t get the headlight up

[98TXRed]

The gear on the passenger-side headlight finally died in the down position and I can’t get the door into the open position. The manual knob just free-wheels and I cannot “ease the headlight up by slightly tugging” as stated in thethe replacement instructions for the brass gear. Do I have to take a crowbar to it (just kidding)? And, yes, I waited too long to repair it (and I am still hearing it from my wife). Any helpful suggestions … anyone?

 

[Patrick]

This sounds like you may have a motor/gear issue to me. Is the motor making any noise when you try turning on the headlight? C4C5 Specialist may have some ideas here, but I think you may be looking at needing to replace the headlight motor.

-Patrick

 

[98TXRed]

Yes, the motor is turning. I need to replace the gear, but I cannot get the headlight to open as the manual knob is freewheeling and I cannot pull the light up. C4C5 (or anyone else), any suggestions?

 

[wishuwerehere82]

It has been about a year since I was inside my headlight assembly. But if I remember correctly, there are a couple of bolts that hold the motor onto the housing that are accessible from the inboard side of the housing. There is one screw that connects the headlamp housing to the motor lever, but I don't think you can get to it with the lamp down.
So if you unbolt the motor, you should be able to lift the headlamp up and disconnect the lever to get the motor out.

 

[Patrick]

98TXRed,
I think it might be worth your effort to send a PM to C4C5Specialist with a link back to this thread- sometimes, the threads in the Tech forum get overwhelmed with other subjects, and they don't catch Paul's attention unless you point it out to him.

As for the actual headlight problem, have you done a forum search for other threads where this problem has been brought up? When I tried, prior to my earlier post, I found that the motor/gear issue was the most frequent culprit of headlight problems in C5's, but that the symptoms being described weren't exactly like yours.

Let us know your findings as you investigate, and please... contact C4C5Specialist by PM if you're still in the dark (pun not intended, directly ) to seek some assistance.

-Patrick

 

[98TXRed]

Thanks, I will contact C4C5 directly. I really am at a loss. Maybe … no, I know, that C4C5 can help!

 

[wishuwerehere82]

Here is a thread about removing the motor.
http://www.corvetteactioncenter.com/forums/showthread.php?t=15184&page=2&highlight=headlight+motor
And another
http://www.corvetteactioncenter.com/forums/showthread.php?t=25960&highlight=headlight+motor

For replacement gears.
http://www.rodneydickman.com/corvette.html

 

[98TXRed]

I finally got the headlight up. Apparently, this was the perfect storm; the gear and bumper had totally come apart, so the manual knob to raise the headlight was just free-wheeling, and the linkage between the headlight and the motor had got into a locked position! Anyway, I got the motor apart and all the little pieces of the gear and bumper out. The rebuild was a snap. Even thought the driver’s side headlight was working ok, I decided to do it also and it was a good thing I did as the plastic gear was starting to crack.

Special kudos goes to the rebuild kit from Rodney Dickman’s. The detailed instructions are easy to follow and everything is provided in the rebuild kit: brass gear (get rid of that cheap plastic OEM gear), bumper, grease, and gasket. I wish that all rebuild kits were as customer-friendly as this kit!

 

[Patrick]

I finally got the headlight up. Apparently, this was the perfect storm; The rebuild was a snap. Even thought the driver’s side headlight was working ok, I decided to do it also and it was a good thing I did as the plastic gear was starting to crack.

Special kudos goes to the rebuild kit from Rodney Dickman’s. The detailed instructions are easy to follow and everything is provided in the rebuild kit: brass gear (get rid of that cheap plastic OEM gear), bumper, grease, and gasket. I wish that all rebuild kits were as customer-friendly as this kit!

Excellent update, 98TXRed. Glad to hear you got that sorted out, and as quickly as you did. I hate hearing stories about Corvettes with the permanent "wink" or non-functional headlights on one side. Thanks for the information about the rebuild kit, too. Many may find that helpful!


-Patrick

 

[wishuwerehere82]

Glad everything worked out.