Rebuilt my headlight motor today...

[Edmond]

and it only took me 4.5 hours! Okay, I cheated with the help of my father but I did the majority of the work. The toughest parts were probably when we took the cover off the plastic gear. We were both anticipating what the bushing would look like and when I finally popped that gear off to reveal the bushings: there weren't any bushing left! :L It was just some beige looking rock salt.

Assembled it and put her back together. Now she runs perfectly.

Big thanks to JonM for the link to the Corvette magazine! Here's to you JonM

 

[vettin1]

I think i might need to rebuild mine. What was the problrm w/them, and, where'd you get the rebuild kit?

Thanx in advance!

 

[Ken]

Congratulations on another job well-done!

... there weren't any bushing left! :L It was just some beige looking rock salt.

I've heard that the gears just grind to dust like that. By the same token, I've heard not to replace the softer plastic gears with the bronze pieces because of the possibilty of damaging the motor itself if the headlamp doors were frozen shut or something.

Did ya take any pitchers when ya rebuilt them?

 

[Edmond]

Ken,

I've read that the bronze gears are a waste of money and I'd have to agree. I didn't see any sign of wear on the plastic one and it's been 15 years. It took me 4.5 hours and that was straight through; didn't even stop to use the bathroom! :L:L

vettin1,

I bought the bushings off eBay and they were quite cheap. I think they were like $4.00 for a set of 3. I bought 2 sets but I'm not going to rebuild the other headlight until it goes out.

 

[Edmond]

I think i might need to rebuild mine. What was the problrm w/them, and, where'd you get the rebuild kit?

Thanx in advance!

Here's the link: http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=33710&item=2424783491

The problem was that the bushings didn't exist anymore! :L:L I bought them from this guy and he is a very fast shipper. I paid on Friday and got them on Monday from Florida to Illinois.

 

[JonM]

Big thanks to JonM for the link to the Corvette magazine! Here's to you JonM

You are welcome...and here's lookin up your address.

 

[Edmond]

Jon,

I must say that your avatars keep getting better and better! Who are those lovely ladies?

 

[JonM]

Jon,

I must say that your avatars keep getting better and better! Who are those lovely ladies?

Jenna & Heidi from the show...Survivor...They are in this months Playboy

 

[vettin1]

Actually, Edmond, I was wondering what was the symptom? Was the light stuck up or down? I ask this because my light is stuck up, all relays changed and wiring looks good. If I manually move the light down it moves up with no prob. It just won't go down. This happened before, changed the isolation relay, everything was fine. However, the light that is stuck up now has moved slower than the other for a WHILE! I guess my question is, with all this info, how do I know if it is the motor, gears or bushings?

 

[JonM]

Vettin1...Your sounds like the classic gear problem like Edmond's

http://www.corvettemagazine.com/2001/december/headlights/head1.asp

 

[Edmond]

Actually, Edmond, I was wondering what was the symptom? Was the light stuck up or down? I ask this because my light is stuck up, all relays changed and wiring looks good. If I manually move the light down it moves up with no prob. It just won't go down. This happened before, changed the isolation relay, everything was fine. However, the light that is stuck up now has moved slower than the other for a WHILE! I guess my question is, with all this info, how do I know if it is the motor, gears or bushings?

My problem was the light wouldn't go up. It would go up after a few tries, but I knew it was just a matter of time before I would have to bite the bullet and change out the bushings. I seriously doubt it would be the gear because my gear had no wear at all and it's 15 years old.

Sorry I can't answer your question! :L

 

[vettin1]

If it is just the gears, would I hear the motor moving when I turn the switch off, or does it just do nothing?

 

[onedef92]

I'll lay odds its your bushings. Go to Home Depot and ask for item number 595609. You will need six of these nylon spacers to repair both headlights. They cost me .69 cents (plus tax) for a pack of three at my local Home Depot store.

Much cheaper than the $7.99 price in MAD, Eckler's and some of the other specialty catalogs and they are the exact same Delrin spacers. Go figure.

If there's a TechTips portal on this Forum search under "headlight bushings." If not, let me know and I'll see if I can get you a copy of the instructions I used when I replaced mine a couple of months ago.