C5 corvette headlight gear

C5 corvette headlight gear DEFAULT

Headlight Motor Gear, Bronze, With Gasket,

  • Replacement Bronze Headlight Gear
  • Stronger Then Plastic
  • Includes: Bronze Gear,Rubber Insert And Gasket

C5 Corvette headlights can suffer from the dreaded droopy eye headlight, or simply stop functioning all together. On Corvettes, this is because the plastic headlight motor gear wears over time against the worm gear. This wear causes major headaches for Corvette owners, and let face it, embarrassing to the look of the car.  Plus, it???s also a serious safety issue. Ecklers headlight motor bronze gear is a simple and easy repair most Corvette owners can do themselves. Remove the headlamp motor, open the housing and replace the plastic gear with our impervious-to-wear bronze unit. A bronze unit offers the delicateness and low sound quality of a plastic unit and will last a lifetime. If your motor has just had it, we have complete replacement units as well, with the bronze unit preinstalled. Ecklers Corvette C5 headlight motor repair kit includes bronze gear, gasket and rubber insert, everything you need to make the job go easy and smooth. 


Corvette bronze headlight motor gear with rubber insert and gasket replaces worn or damaged gear

Corvette bronze headlight motor gear with rubber insert and gasket replaces worn or damaged gear


Combined Cancer/Birth Defect
WARNING This product can expose you to chemicals including BENZEN which is known to the State of California to cause cancer on birth defects or other reproductive harm. For more information, visit www.p65warnings.ca.gov

Sours: https://www.ecklerscorvette.com/corvette-headlight-motor-gear-bronze-with-gaskethtml

Many a C5 owner has heard that unmistakable machine gun sound emanating from the front of the car when turning on the headlights. And if that noise isn’t annoying enough, at least one of the headlights doesn’t come up, or doesn’t go down.

Anyone who has gone through this knows the fix is to replace the factory nylon gear in the headlight motor with a replacement bronze gear.

But what’s up when the gear has been replaced – by a dealer – and it happens again? Certainly the teeth on the bronze gear have not worn down to the point where they disengage from the motor drive gear. When it happened on our subject convertible, we popped the hood and discovered that epoxy used to hold the gear cover on the motor had failed and fortunately was lying beside it. As a result there was enough play on the gear shaft to allow it to disengage from the drive gear and “rat-a-tat-tat-tat-tat-tat!” each time you tried to use the lights.

Corvette Central has a headlight motor rebuild kit ( models here, models here) that offers a perfect solution.  In addition to a bronze gear for those who need it, the C-Central kit also includes a T-bracket that fits over the gear housing cover, keeping it in place even if the epoxy fails.

Follow along with us as we not only rebuild the motors on both headlights of our C5, but using the kit from Corvette Central will prevent us from having any more trouble in the future.

We elected to remove the entire headlight assembly from the car, rather than just the motor. This not only provides easier access, but also allows you to change your headlight bulbs at the same time. A word to the wise: don’t remove both assemblies at the same time. It sure is handy to have a reference when re-installing the assembly.

1. If your headlight isn’t already in the fully up position, you’ll need to get it there manually before removing the assembly. Remove this rubber cap and turn the knob on the back of the headlight motor counter-clockwise until the headlight reaches its apex. It may take quite a bit of turning before the headlight begins to rise.

2. Next, disconnect the power to the headlight. The power connector is located immediately behind the headlight motor. Remove the connector from the tab that holds it in place, lift slightly on the snap that holds the two parts of the connector together and pull apart.

3. Using a Phillips screwdriver, remove the three screws that hold the black plastic headlight bezel in place. Two of the screws are easily accessible on either side of the headlight.  The third is at the back of the bezel on the hood side of the assembly. Then slide the bezel forward to remove.

4. This shows the tab on the top of the bezel that slides onto a clip on the underside of the headlight cover to help hold it in place. As you slide the bezel forward, you’ll need to work it loose from the clip. Pay attention now to how these two pieces mate up. It will make it much easier to reassemble later.

5. Next, remove the headlight cover. This isn’t absolutely necessary, but it certainly will avoid any accidental scratches! Remove the four T Torx screws holding it to the assembly. There are one on each side, and two in back.

6. This shows the positions of the six bolts that hold the headlight assembly in the car.  The front of the car is to the left of the photo. The bolts at the rear (to the right in the photo) require a 10mm deep socket to remove. We found a ¼-inch ratchet works best … it’s a pretty tight fit! Use a ½-inch socket to remove the bolts toward the inside of the engine compartment (at the top of the photo). After removing the bolts, lift the driver’s side headlight assembly out. Be careful not to scratch the front clip or the fender as you lift (note the microfiber towel covering the front clip). The passenger’s side headlight has an additional wiring harness you’ll have to remove before lifting out.

7. This is the driver’s side assembly removed from the car. Note that on this side, the gear cover is still in place. That’s because it’s against the assembly, on the backside. That was not the case with the passenger side, where the cover is toward the engine compartment side and left exposed.

8. Before removing the motor from the assembly, you’ll need to unplug the wiring harness from the back of the bulbs. Note that we labeled the bulbs with the wire color BEFORE removing!

9. Remove the motor from the headlight bracket by loosening the three nuts and bolts shown here. There’s a fourth nut on the back of the shaft in the middle of the gear housing.

Once the nuts and bolts were removed, the gear cover (behind the gear in the photo) is easily separated from the rest of the gear housing. The Corvette Central kit with the t-bracket will solve that problem. If your cover doesn’t remove so easily, gently pry it from the rest of the housing. It comes pressure fitted from the factory, so if your motor hasn’t been previously repaired, you’ll need to take your time so you don’t break the cover, or the tabs on the inside of the cover. This side had been repaired by a dealer at one time … though the gear was replaced with another nylon gear! We’ll fix that too!

Since this motor had recently been repaired by a dealer, it appears relatively clean.  Oftentimes when replacing a nylon gear, you will find broken teeth, rust and other grime mixed in with the grease.

Clean out the gear housing of all debris and grease. If your motor has been previously repaired, remove the excess epoxy. It should easily peel from the cover and/or the gear housing.

The Corvette Central kit comes with a bronze gear and the rubber insert. When reinstalling the shaft, make sure the flanges fit flush against the rubber insert. Liberally grease the bronze gear teeth, the drive gear, and the shaft using the grease supplied with the kit. Be careful not to get grease on the edge of the gear housing or the cover, as the epoxy won’t adhere.

Place the new bronze gear/rubber/insert/shaft into the housing. Mix the two-part epoxy that comes with the Corvette Central kit, apply to the underside lip of the cover and replace the cover. The instructions indicate there’s no need to clamp, but we weren’t taking any chances! Let the glue set for 24 hours.

When reattaching the motor assembly to the headlight bracket, place the Corvette Central T-bracket in position, matching up with holes that accept the nuts and bolts you removed the day before. Once the motor is secure, reattach the bulb harness, and place the headlight assembly, cover, and bezel back into their respective positions, using the other headlight as your guide. Before reattaching the power to the motor, manually lower and raise the headlight a few times to make sure all is functioning properly. Reconnect the power wiring harness and give it a test! No more machine gun sound, the headlight goes all the way up and all the way down, and with that T-bracket, it should never need repaired again!

 

For your information:

 

Corvette Central

()

www.corvettecentral.com

Story Mark Kaufman (Reprinted with permission)

C5 headlight repairheadlight repairt-bracket

Sours: https://tech.corvettecentral.com//09/c5-headlight-repair-with-a-t/
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  C5 Corvette

Replacement Headlight Gears

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NEW from Rodney Dickman

*Each brass headlight gear now includes a new heavy duty rubber bumper


These new CNC machine made brass gears and new heavy duty rubber bumpers are made to replace the failure prone plastic headlight gears and rubber bumpers used in the C5 Corvette headlight motors. If your Corvette headlight motor(s) run but do not properly open or close, or your headlight motor(s) make an awful racket once fully open or fully closed, this product is for you.

Fits Firebird , Corvette and Saturn SC Coupe Replaces damaged gear inside motor.
OEM#'s: , , ,

 

Precision CNC machining ensures an exact match and perfect fit.






New brass gear and new rubber bumper installed in a C5 headlight motor.


 Why buy a fragile new $+ headlight motor when you can make your existing headlight motors heavy duty with this new brass gear and new heavy duty rubber bumper.

Note: When I first started selling these new brass gears for the C5 Corvette headlight motors I received feedback from some C5 owners stating that some of the OEM rubber bumpers were found to be in very poor condition or showed some level of degradation. At the same time many of these OEM rubber bumpers still appeared to be in good condition.  This made it necessary for me to have the rubber bumpers reproduced.  Even if the OEM rubber bumper inside the original gear appears to be in good condition I feel it may not last the life of the new brass gear. I have had these rubber bumpers reproduced in a tougher rubber that should last the life of the motor. I now include one of these new rubber bumpers with each C5 headlight gear ordered.
 

Complete detailed step by step instructions are included with each gear.  This is an easy repair most C5 owners can do themselves.  Rebuilding the headlight motor is a fairly easy task.  It is harder to take the headlight motor out of the car then it is to rebuild them

* A packet of silicone grease is included with each new gear kit.  This silicone grease will never dry out like conventional grease.  The gear kit also includes a new side cover gasket.  The side cover is held on with three screws.  The gear kit includes a packet of urethane glue that is necessary to re-seal the side cover and a new steel side-cover brace.  The side cover is glued on but it is easy to open to do the repair.

Late + Kits are NEW and IMPROVED

Now upgraded to include a newly engineered special steel brace with a special plastic support bushing for the late type plastic housings. I have noticed a few glue joint failures. Glue joint failures happen because the plastic that these headlight motors are made of does not take any adhesive well. The glue joint surface is small and once installed it has to take a tremendous force that occurs when the headlight gets full open and full closed and stops abruptly. I have added a special stamped steel brace with a special plastic bushing. This brace and bushing does two things. It applies a slight pressure against the side cover helping to eliminate side cover glue failures. But most importantly it adds a new bearing surface to support the shaft thus removing all the pressure of the shaft from the side cover and transferring it to this new brace. Once installed this repair should easily last the life of the car.

Why rebuild your headlight motor with a cheap plastic gear that will not last, and also, why risk having a glue joint failure? My brass gear ensures the actuator motor will last and the glue joint will not fail.

NOTE #1: There are 2 variations of the headlight actuator motor assemblies used on the and up C5 Corvettes. The motor assembly (and some early models) is all aluminum and has a removable side cover that is held on with 3 machine screws. The gear kit for the motor assembly includes a new side cover gasket. The late + motor assembly is partially plastic has a glued on plastic side cover. This cover needs to be pried off (broken at the factory glue joint) to replace the worn gear. The cover is easy to pry off and I include a packet of urethane glue to reglue it back on. Included with each replacement gear is a packet of silicone grease that will never dry out like the grease used by the original manufacturer. Also included: Complete detailed rebuilding instructions and how to remove the headlight motor assembly from the car.

NOTE #2: If you have a C5 Corvette there is the possibility that one or both of the early aluminum type headlight motor(s) have been replaced with the newer + style plastic type headlight motor(s). To ensure you receive the correct kit please check to see if the headlight motor(s) in your (and early ) C5 are plastic or aluminum. The aluminum housing style is the original equipment used on the (and some early ) C5 Corvettes. They will have 3 screws holding the side cover one while the + headlight motor assemblies are plastic and the side cover is glued on. This newer style headlight motor change can occur because the style motors are no longer available through GM. If a previous owner or a GM dealer has replaced a headlight motor in a they may have installed the newer + style. A quick check will ensure that you order the correct rebuild kit.

If you are not sure which style motor you have look at the pictures below.

The early aluminum housing type motor assembly is on the left and the late plastic type motor assembly is on the right.

 

Upgrade your older brass headlight gear kits with the new steel brace and better urethane adhesive.

Fits Firebird , Corvette and Saturn SC Coupe Replaces damaged gear inside motor.
OEM#'s: , , ,

        
 Price is only

$43 each Or $85 for two early kits

$or $87 for two late + C5 kits

Add  $6 shipping for one or $7 for two.

* WI residents please add  5% sales tax.  $ for one or $ for two.

 

I accept VISA, MASTERCARD, PAYPAL, CHECK, and MONEYORDER. 

To order, 

E-Mail me at:    [email protected]

OR order online on my  www.rodneydickman.com Fiero site.

Just click on the "Fiero" page link, and then look in the "Electrical" section.

Or Call:

Rodney Dickman's Vehicle Accessories.  ()

Or Send Check or Money Order to:

Rodney Dickman

Treeview Drive

Caledonia, WI.

*Checks may delay shipping by days, or until the check clears the bank.  Money Orders ship immediately.


Q: Why does the headlight motor of my Vette keep running after I turn the lights off? What's that strange buzzing?

A: There is a little plastic gear that has probably stripped out inside the headlight mechanism. This gear is replaced with my Brass Replacement Headlight Gears.  This is an easy repair most C5 owners can do themselves.


1. Manually crank malfunctioning headlamp to the full up position, or turn headlights on if they will raise on their own.
2. Remove black plastic shroud around headlamp to gain easier access to bolts for motor.
3. Remove motor assembly.   It is held on by 3 bolts. .
4. Take the motor to the work bench and remove the screws holding the cover. Or, depending on year, carefully pry off the cover from the gear box. 
5. Once the cover is off, you will see a nylon gear about 2 inches in diameter. There should be a spot on it where the teeth are damaged or ground off from the metal gear that meshes with it. This is where the problem resides. GM used a plastic gear, that can't stand up to the rigors of daily use. 
6. With the side cover removed,  simply pull the old gear and shaft out of the motor and pull the old gear and bumper off the shaft. Install the new brass gear and new rubber bumper on to the shaft and put it back in the motor housing. There are no tools required to do this step. All the parts slip together.
7.  Screw cover back in place, or use some epoxy glue (included) to glue the cover back on. Re-install the motor in the reverse order.

 

QUESTIONS? E-Mail me

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Take a look here for my links page. If I sell it, you can find it here!

www.execpc.com/~rodney1/products

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Copyright Rodney Dickman's Vehicle Accesories. Caledonia, WI.

Sours: http://my.execpc.com/~rodney1/vettegears/index.htm
How To Remove/Fix C5 Headlight Motor

C5 Corvette Brass Headlight Motor Repair Gear Kit NEW

These kits are complete. There is nothing else to buy!

Do not waste your time and money on the aftermarket plastic gears!  They are very poor quality and typically last a very short time. Do it right the first time!! 

CNC machine made brass gear to replace the failure prone plastic headlight gear in the C5 Corvettes. Easy to install. Why buy a fragile OEM replacement motor assembly when you can make your motor assembly heavy duty with this replacement gear.


Re-Engineered for even longer lasting life! Now upgraded to include a newly engineered special steel brace with a special plastic support bushing. I have noticed glue joint failures in the late C5 plastic housing motors. Glue joint failures happen because the plastic that these headlight motors are made of does not take any adhesive well. The glue joint surface is small and once installed it has to take a tremendous force that occurs when the headlight gets full open and full closed and stops abruptly. For the late C5 headlight gear kits I have added a special stamped steel brace with a special plastic bushing. This brace and bushing do two things. It applies a slight pressure against the side cover helping to eliminate side cover glue failures. But most importantly it adds a new bearing surface to support the shaft thus removing all the pressure of the shaft from the side cover and transferring it to this new brace. Once installed this repair should  last the life of the car. The early ( and some early ) C5's have an aluminum housing and do not need this special brace. Those headlight motor assemblies are very heavy duty and only require a new gear and rubber bumper.
 New design for the late style (Late ) C5 plastic housing motors!

Corvette Headlight Gear

Corvette Headlight Reapair Kit

Late C5 plastic housing with steel brace installed

Corvette Headlight Gear

 

Symptoms of a failed gear in the headlight motor: 
If your headlight motor makes a grinding noise when turned on or turned off (this usually happens at the full open and full closed position) this is what you need to repair your headlight motor. If you do not repair or replace your headlight motor once this begins to happen - sooner or latter the headlight will not raise at all. 

The OEM plastic gear and the rubber bumper are the weak parts in these headlight motors. Once rebuilt with my new heavy duty gears the headlight motors should last the life of your car. The rubber bumper will not last forever but is made of a quality rubber. Like any rubber product it can wear out. 

Some are not always sure where the thin white plastic washer goes. So I'm putting a picture here. It goes on the output shaft like this on both sides:

 

NOTE #1:   There are 2 variations of the headlight actuator motor assemblies used on the and up C5 Corvettes. The motor assembly (and some early models) is all aluminum and has a removable side cover that is held on with 3 machine screws. The gear kit for the motor assembly includes a new side cover gasket. The late + motor assembly is partially plastic (the gear case is plastic - the motor is steel) and it has a glued on plastic side cover. This cover needs to be pried off (broken at the factory glue joint) to replace the worn gear. The cover is easy to pry off and I include a packet of urethane glue to reglue it back on. Included with each replacement gear is a packet of high temerature grease that will not dry out quickly like the grease used by the original manufacturer. Also included: Complete step by step detailed rebuilding instructions and how to remove the headlight motor assembly from the car. Note from a C5 owner who is a chemist: "If you do accidentally get grease on the joint, one C5 owner says you can successfully clean it off with acetone, and the urethane adhesive will then bond to the housing."

NOTE #2: If you have a C5 Corvette there is the possibility that one or both of the early aluminum type headlight motor(s) have been replaced with the newer + style plastic type headlight motor(s). To ensure you receive the correct kit please check to see if the headlight motor(s) in your (and early ) C5 are plastic or aluminum. The aluminum housing style is the original equipment used on the (and some early ) C5 Corvettes. They will have 3 screws holding the side cover one while the + headlight motor assemblies are plastic and the side cover is glued on. This newer style headlight motor change can occur because the style motors are no longer available through GM. If a previous owner or a GM dealer has replaced a headlight motor in a they may have installed the newer + style. A quick check will ensure that you order the correct rebuild kit. 

If you are not sure which style motor you have look at the pictures below. The early aluminum housing type motor assembly is on the left and the late plastic type motor assembly is on the right.

Upgrade your older brass headlight gear kits with the new steel brace and better urethane adhesive. Click here for these parts.

Also fits the  Firebird  and Saturn SC Coupe Replaces damaged gear inside motor.  OEM#'s: , , ,

Late C5 plastic housing motor with steel brace installed
Early aluminum type ( and early )                  Late and plastic housing type

Note: The pictures above show one side of the headlight motor. The opposite side is similar. On the early aluminum type headlight motors (picture on the left above) you can see the 3 small screws on the passenger side motor but on the driver side motor the 3 small screws are facing away from you and can not be seen.

This is a picture of the plastic type housing with the headlight motor still in the car in the C5. The ribs in the cover tell you it is the late plastic type. If the cover is smooth is is the early aluminum type.

Sours: https://www.vettenuts.net/index.php?l=product_detail&p=

Gear headlight c5 corvette

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C5 Corvette 5 Minute Headlight Motor Repair!!! 97- early 2000

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