Al Rebuilds a C5 Headlamp Motor
Al Forey sent the following write up on his latest C5 Project
For C5ers who have a headlight that won't close or open or sounds like a machine gun when doing so.
Before going to Bloomington Gold, I replaced the headlight motor gear on the passenger side of my 2001.
It would open and close then sound like a machine gun for 3 seconds after closing.
I purchased a rebuild kit from Corvette Central ($59 shipped) that has a brass gear to replace the factory nylon gear (see photo) for one headlight.
After the headlight cover (body color) and black bezel around the headlights are removed, three nuts and 3 bolts anchoring the headlight assembly into the car are removed.
The fasteners are hard to get at and are almost impossible to see. Also disconnect the battery and 2 connectors.
After carefully observing the orientation of everything and removing the actuator, the plastic gearbox must be pried open at the end cover that is glued. The errant gear, steel shaft, and rubber internal bumper washer are removed. The replacement parts are then installed with the shaft in proper rotation.
The gearbox is then epoxied shut and clamped overnight.
The entire headlight assembly is then reinstalled.
About 3 hours for removal and repair and about 1 1/2 hours to reassemble and adjustment.
Now I need to replace the driver side gear before it fails.
Pictures show the errant gear and process.
On another front, I replaced the 2 bulbs in the trunk lights and 2 bulbs lighting the floorboards.
I always felt that the factory lights were too dim (think candlelight).
I purchased LED bulbs from Super Bright LEDS online.
They are inexpensive, only take moments to install, last a long time, do not get as hot, and draw less current.
I will replace other bulbs in the car.
As a sidebar: I replaced all the landscape light bulbs at home, supplied by the same source.
For C5ers who have a headlight that won't close or open or sounds like a machine gun when doing so.
Before going to Bloomington Gold, I replaced the headlight motor gear on the passenger side of my 2001.
It would open and close then sound like a machine gun for 3 seconds after closing.
I purchased a rebuild kit from Corvette Central ($59 shipped) that has a brass gear to replace the factory nylon gear (see photo) for one headlight.
After the headlight cover (body color) and black bezel around the headlights are removed, three nuts and 3 bolts anchoring the headlight assembly into the car are removed.
The fasteners are hard to get at and are almost impossible to see. Also disconnect the battery and 2 connectors.
After carefully observing the orientation of everything and removing the actuator, the plastic gearbox must be pried open at the end cover that is glued. The errant gear, steel shaft, and rubber internal bumper washer are removed. The replacement parts are then installed with the shaft in proper rotation.
The gearbox is then epoxied shut and clamped overnight.
The entire headlight assembly is then reinstalled.
About 3 hours for removal and repair and about 1 1/2 hours to reassemble and adjustment.
Now I need to replace the driver side gear before it fails.
Pictures show the errant gear and process.
On another front, I replaced the 2 bulbs in the trunk lights and 2 bulbs lighting the floorboards.
I always felt that the factory lights were too dim (think candlelight).
I purchased LED bulbs from Super Bright LEDS online.
They are inexpensive, only take moments to install, last a long time, do not get as hot, and draw less current.
I will replace other bulbs in the car.
As a sidebar: I replaced all the landscape light bulbs at home, supplied by the same source.
