I just did a search here on the headlight bushing and found several threads about headlight ills but not a good rundown of the process. I know I could dig out my FSM but the older I get the heavier that book gets! LOL

I thought Andy had a write-up on the process but I couldn't find it.

If not I'll get my big ol' butt up and go dig my manuals out and find my reading glasses to see what has to be done.


Oh yeah... my headlights have been developing the hesitation and then the bump, bump, bump run-on after closing.

^^Well, there is that one sticky on "the other forum"....but the pictures are removed....

Then here is a good one that is specific to your years

http://www.corvettemagazine.com/2002/february/c4lights/light1.asp

It shows a few ok things. There are things I would revise from that document but I don't remember the differences now....it's been almost two years since I broke into mine.

It's one of things where you are following step by step and you find yourself kinda not understanding what they are trying to say...then you just bull your way ahead only to discover your common sense would have been better off to start with......that sort of thing.

There is a sticky on CF in the C4 tech section. It is good but includes a lot of things you don't need to do just to replace the bushings.

Remove the complete H/L assembly from the car. Simply unplug the wire harness, two screws at the bottom of the assembly and two nuts on each side.

Put a towel or similiar on your work bench and lay the assembly upside down on it. You will see 2 torx head screws holding the motor assembly to the H/L bracket. You could just loosen them, but just as easy to take them out.
The only reason for this step is that you can not remove the inner torx head screw in the next step without moving the motor bracket about 1/4".

You will see a roll pin that connects the motor shaft to the linkage. Be sure to make a note of how the linkage is hooked up so you put it back the same way. Tap the pin out and then there are three torx head screws (two on the open side and one on the back side towards the HL) and you should now have the motor loose. There are 3 screws on the cover to get to the bushings. Remove the cover and pull the gear up and out. If it is tight then loosen the worm gear one or two full turns (remember how many so you can turn it back when going back together). DO NOT TAKE OUT THE SCREWS THAT ATTACH THE MOTOR TO THE GEAR HOUSING. You might not be able to get the brushes back in place. There are also a couple of thin washers on the shaft side of the gear, be careful not to lose them. Clean out the crud and go back together in reverse order.

I hope I didn't forget anything.