Headlight issue, what do you think. [Forums - C4 Technical]

C4 Technical > Headlight issue, what do you think.
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Steve40th	Headlight issue, what do you think.	#1
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	As you see in this video, the headlight goes halfway then stops, as the motor continues to spin. It shuts just fine. I took the headlight apart, the gears (bronze) were fine, along with the grease and delrin bushings. So, is it within the motor. All the links associated with the headlight are fine. http://s280.photobucket.com/albums/kk ... o-2011-06-23-10-24-49.mp4
	Posted on: 2011/6/24 18:20
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bogus	Re: Headlight issue, what do you think.	#2
Grand Imperial Pooh-Bah San Pedro, CA 20859 Posts Member since: 2005/9/7 0:00	easily something could be bound up. I would order a use headlight mechanism from Vette2Vette... There about $100.00 or so. Saves the angst of repair. Just swap it.
	Posted on: 2011/6/24 19:32
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Steve40th	Re: Headlight issue, what do you think.	#3
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	Quote: bogus wrote: easily something could be bound up. I would order a use headlight mechanism from Vette2Vette... There about $100.00 or so. Saves the angst of repair. Just swap it. Nothing seems to be binding as I watch it with the hood open. Its doesnt do it every time. Its almost as if it looses gearing, as if the teeth are stripped, then it grabs. But, the worm gear is fine. Are there gears in the motor that can be replaced?
	Posted on: 2011/6/24 19:35
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1Fast04Vert	Re: Headlight issue, what do you think.	#4
Elite Guru The hills of N. Georgia 2424 Posts Member since: 2007/12/30 0:00	Isn't there an adjustment on the worm gear?
	Posted on: 2011/6/24 21:47
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Steve40th	Re: Headlight issue, what do you think.	#5
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	Quote: 95vette wrote: Isn't there an adjustment on the worm gear? No idea? I will check the fsm
	Posted on: 2011/6/24 22:19
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BillH	Re: Headlight issue, what do you think.	#6
The Stig Moderator Reno 22702 Posts Member since: 2007/12/25 0:00	Quote: Steve40th wrote: Quote: bogus wrote: easily something could be bound up. I would order a use headlight mechanism from Vette2Vette... There about $100.00 or so. Saves the angst of repair. Just swap it. Nothing seems to be binding as I watch it with the hood open. Its doesnt do it every time. Its almost as if it looses gearing, as if the teeth are stripped, then it grabs. But, the worm gear is fine. Are there gears in the motor that can be replaced? No just the worm & the bronze. Also check the electrics out, FSM chart one (Headlights stay open or closed). Possibly a bad ground (intermittent contact). Probably not but needs to be checked. In the vid did you cycle the headlight switch on than off? Manually check: Spin it open by hand with the knob (yea, I know, it takes forever). Get the door open close to where you saw it stop. Put some slight resistance on the door with your other hand and spin the knob. Do you feel anything as it moves thru the place where it stopped before? More play in the knob, play in the headlight assy.? You will have to check for looseness (or bind) by hand.
	Posted on: 2011/6/24 23:03
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BillH	Re: Headlight issue, what do you think.	#7
The Stig Moderator Reno 22702 Posts Member since: 2007/12/25 0:00	Quote: Steve40th wrote: Quote: 95vette wrote: Isn't there an adjustment on the worm gear? No idea? I will check the fsm Nothing in the FSM (figures don't it?).
	Posted on: 2011/6/24 23:04
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Matatk	Re: Headlight issue, what do you think.	#8
Webmaster SW Chicago Burbs 22803 Posts Member since: 2008/1/7 0:00	I'd inspect the linkage carefully. I had a washer slightly bent on mine that caused it to only open partially. I dissembled it, pounded the washer flat, and it worked fine after that. Matthew
	Posted on: 2011/6/24 23:39
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BillH	Re: Headlight issue, what do you think.	#9
The Stig Moderator Reno 22702 Posts Member since: 2007/12/25 0:00	Quote: Matatk wrote: I'd inspect the linkage carefully. I had a washer slightly bent on mine that caused it to only open partially. I dissembled it, pounded the washer flat, and it worked fine after that. Matthew Good point.
	Posted on: 2011/6/24 23:44
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Steve40th	Re: Headlight issue, what do you think.	#10
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	Quote: BillH wrote: Quote: Steve40th wrote: Quote: bogus wrote: easily something could be bound up. I would order a use headlight mechanism from Vette2Vette... There about $100.00 or so. Saves the angst of repair. Just swap it. Nothing seems to be binding as I watch it with the hood open. Its doesnt do it every time. Its almost as if it looses gearing, as if the teeth are stripped, then it grabs. But, the worm gear is fine. Are there gears in the motor that can be replaced? No just the worm & the bronze. Also check the electrics out, FSM chart one (Headlights stay open or closed). Possibly a bad ground (intermittent contact). Probably not but needs to be checked. In the vid did you cycle the headlight switch on than off? Manually check: Spin it open by hand with the knob (yea, I know, it takes forever). Get the door open close to where you saw it stop. Put some slight resistance on the door with your other hand and spin the knob. Do you feel anything as it moves thru the place where it stopped before? More play in the knob, play in the headlight assy.? You will have to check for looseness (or bind) by hand. I did cycle the headlight switch in the video. I will manually open it and check for bind. I will also look for bad connections etc. I am able to turn the knob and manually open the headlight.
	Posted on: 2011/6/24 23:58
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Steve40th	Re: Headlight issue, what do you think.	#11
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	Quote: Matatk wrote: I'd inspect the linkage carefully. I had a washer slightly bent on mine that caused it to only open partially. I dissembled it, pounded the washer flat, and it worked fine after that. Matthew HMM, will look into this more carefully. Thanks
	Posted on: 2011/6/24 23:59
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Matatk	Re: Headlight issue, what do you think.	#12
Webmaster SW Chicago Burbs 22803 Posts Member since: 2008/1/7 0:00	Quote: Steve40th wrote: Quote: Matatk wrote: I'd inspect the linkage carefully. I had a washer slightly bent on mine that caused it to only open partially. I dissembled it, pounded the washer flat, and it worked fine after that. Matthew HMM, will look into this more carefully. Thanks Mine would open fine with the knob, but electrically would not open.
	Posted on: 2011/6/25 0:18
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Steve40th	Re: Headlight issue, what do you think.	#13
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	Here is another video with hood open, as you can see it opens and closes fine. But, the motor spins for a while after they are open. The right side motor stops as soon as headlight opens. http://s280.photobucket.com/albums/kk ... o-2011-06-24-14-15-25.mp4
	Posted on: 2011/6/25 0:30
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BillH	Re: Headlight issue, what do you think.	#14
The Stig Moderator Reno 22702 Posts Member since: 2007/12/25 0:00	Quote: Steve40th wrote: Here is another video with hood open, as you can see it opens and closes fine. But, the motor spins for a while after they are open. The right side motor stops as soon as headlight opens. I just ran down into the shop and spun mine, Steve. I think you have a gear mesh thing. My knob stops exactly when the headlight bucket stops, both open & close.
	Posted on: 2011/6/25 0:40
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BillH	Re: Headlight issue, what do you think.	#15
The Stig Moderator Reno 22702 Posts Member since: 2007/12/25 0:00	OK, this peaked my curiosity. There is an adjustment on the worm gear shaft. This is not much different from the C2 drive/worm. If you look at the last 2 pics here, the last pic shows the adj. screw and locknut (lefthand side of the gear housing). that set screw pushes on the wormgear shaft and controls the degree of mesh. http://www.corvette-guru.com/modules/ ... p?topic_id=12705&forum=31 There is the same slotted screw and locknut on the C4. But first, check for play in the motor knob. You'll have to turn the knob 1/2 to 1 turn off the stop (when the headlight is fully closed). Now, is there any play in the knob at all either rotating it or pulling it up & down? There should be zero play rotating it gently back & forth. I don't think I'd try to adjust that with the motor on the car, I'd do it on the bench. What I would do is lightly tighten that slotted screw down until you can feel it hit the shaft. Then back it off an 1/8th turn and tighten the locknut. Note, I do Matt's linkage check first. In the pic, the screwdriver's pointing to the adj. screw. Attach file: 2006-04-07 00-48-29_0003.JPG (0.00 KB)
	Posted on: 2011/6/25 1:24
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Steve40th	Re: Headlight issue, what do you think.	#16
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	Quote: BillH wrote: OK, this peaked my curiosity. There is an adjustment on the worm gear shaft. This is not much different from the C2 drive/worm. If you look at the last 2 pics here, the last pic shows the adj. screw and locknut (lefthand side of the gear housing). that set screw pushes on the wormgear shaft and controls the degree of mesh. http://www.corvette-guru.com/modules/ ... p?topic_id=12705&forum=31 There is the same slotted screw and locknut on the C4. But first, check for play in the motor knob. You'll have to turn the knob 1/2 to 1 turn off the stop (when the headlight is fully closed). Now, is there any play in the knob at all either rotating it or pulling it up & down? There should be zero play rotating it gently back & forth. I don't think I'd try to adjust that with the motor on the car, I'd do it on the bench. What I would do is lightly tighten that slotted screw down until you can feel it hit the shaft. Then back it off an 1/8th turn and tighten the locknut. Note, I do Matt's linkage check first. In the pic, the screwdriver's pointing to the adj. screw. I will look at it tomorrow. Still fighting a C5 clutch. First ZO6 we did went pretty darn smooth, this one, same year etc, is a pain.
	Posted on: 2011/6/25 7:10
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Steve40th	Re: Headlight issue, what do you think.	#17
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	The shaft that goes through the housing that holds the gear/bushings etc was stripped. So, I pinned the shaft to the housing. All good now. [IMG]http://i280.photobucket.com/albums/kk189/rivary0006/2011-07-01135128.jpg[/IMG]
	Posted on: 2011/7/2 4:44
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Matatk	Re: Headlight issue, what do you think.	#18
Webmaster SW Chicago Burbs 22803 Posts Member since: 2008/1/7 0:00	Excellent! Glad you found the solution to that tricky problem...very strange.
	Posted on: 2011/7/2 11:39
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Steve40th	Re: Headlight issue, what do you think.	#19
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	Quote: Matatk wrote: Excellent! Glad you found the solution to that tricky problem...very strange. I think the problem stems from using glass housings instead of the lighter factory plastic headlights. And over time it was just too much stress on the teeth.
	Posted on: 2011/7/2 20:23
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Matatk	Re: Headlight issue, what do you think.	#20
Webmaster SW Chicago Burbs 22803 Posts Member since: 2008/1/7 0:00	Quote: Steve40th wrote: Quote: Matatk wrote: Excellent! Glad you found the solution to that tricky problem...very strange. I think the problem stems from using glass housings instead of the lighter factory plastic headlights. And over time it was just too much stress on the teeth. Hmmm...must be later years. On the early cars they were glass housings...I converted to plastic. I noticed once I converted the headlights would spin a lot faster. Matthew
	Posted on: 2011/7/3 11:46
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95Vert	Re: Headlight issue, what do you think.	#21
Senior Guru Aiken, SC 440 Posts Member since: 2008/6/2 1:15	Sorry to raise this issue again, but I'm having the same problem on my lef theadlight. Motor spins for a while after the headlight closes and opens and the headlight will only come up halfway and then feels loose, bouncy like in the holder. I wonder if my "shaft" is stripped as well, I just don't know what shaft is being referenced. I also have the glass housings as my lights are Cibie and I don't want to switch to inferior lighting. I'm trying to see some of the pictures but no luck. Is there any help for that. Trying to figure out what is stripped. (This is what a search gets you, more questions )
	Posted on: 2012/7/27 15:47

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BrianCunningham	Re: Headlight issue, what do you think.	#22
Senior Guru Boston, MA for the most part :) 7763 Posts Member since: 2007/12/30 0:00	Left or the right? I've had mine hang up when the fan relays came loose. There's not much clearance.
	Posted on: 2012/7/27 15:59
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95Vert	Re: Headlight issue, what do you think.	#23
Senior Guru Aiken, SC 440 Posts Member since: 2008/6/2 1:15	Left side, like the original poster I believe...
	Posted on: 2012/7/27 18:39

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bogus	Re: Headlight issue, what do you think.	#24
Grand Imperial Pooh-Bah San Pedro, CA 20859 Posts Member since: 2005/9/7 0:00	I would replace the bushings... inside the gear are these three plastic bushing thingies... they get beat to crap and then die.... turn to powder. Replace those and your headlights should be fine.
	Posted on: 2012/7/27 19:05
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Steve40th	Re: Headlight issue, what do you think.	#25
Elite Guru 1114 Posts Member since: 2005/12/20 0:00	Andy, you sound like you are talking about old people dying..LOL
	Posted on: 2012/7/27 19:32
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1Fast04Vert	Re: Headlight issue, what do you think.	#26
Elite Guru The hills of N. Georgia 2424 Posts Member since: 2007/12/30 0:00	Quote: bogus wrote: I would replace the bushings... inside the gear are these three plastic bushing thingies... they get beat to crap and then die.... turn to powder. Replace those and your headlights should be fine. It is a relatively easy do it yourself project and the bushings are the same as Ford used in their power windows, so you can get them at any auto parts store. Here is a link to the process. And the only wiring you have to mess with is simply unplugging the harness at the connector. http://api.viglink.com/api/click?form ... glnk_jsonp_13434195270503
	Posted on: 2012/7/27 19:56
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BillH	Re: Headlight issue, what do you think.	#27
The Stig Moderator Reno 22702 Posts Member since: 2007/12/25 0:00	Quote: 1Fast04Vert wrote: It is a relatively easy do it yourself project and the bushings are the same as Ford used in their power windows, so you can get them at any auto parts store. You can also get them at Home Depot.
	Posted on: 2012/7/27 22:07
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