1993 ZR-1 Headlights issue

[dnobull]

I just had a ratcheting issue with my headlights when they open. The same ratcheting sound happens when I close the head lights. I can see that the left headlight is not opening all the way.

I fear taking this to the average chevy dealer in the Kansas City area but I wonder if anyone knows someone in the area who is smart enough to fix this issue.

If I knew what parts to purchase I would do that first

Open to suggestions'

Dave Noble
Ruby #180

[DRM500RUBYZR-1]

Pellets / bushings
any supplier has them
cost under $10.00
Marty

[dnobull]

Thanks Marty,

I am not sure what bushings you are referring to. I am becoming more sure that the plastic gears are striped. I found a brass gear but they are about $39.00 each. I noticed that this is on Ebay so I would like to buy direct from the guy that makes them

This link shows what I have found:

https://www.ebay.com/i/161826538170?chn=ps&norover=1&mkevt=1&mkrid=711-117182-37290-0&mkcid=2&itemid=161826538170&targetid=541454150532&device=c&mktype=pla&googleloc=9023206&poi=&campaignid=6470552634&mkgroupid=81274458647&rlsatarget=pla-541454150532&abcId=1139336&merchantid=108134507&gclid=CjwKCAiA_MPuBRB5EiwAHTTvMfWjBKeeo6no0Eqcp99C aMoH3Nonoz9MySlbUF8tGszNKMMK7vtPrBoCynEQAvD_BwE

[Demps]

http://www.corvettemagazine.com/tech-articles/1988-1996-corvette-headlight-motor-bushing-installation/

Local auto parts stock poly-bushings for older manual windows (3 pack).

Ted

[Paul Workman]

Yep...stripped nylon gear/drooping headlight. Easy fix for even the novice DIY'er.
I opted for the bronze replacement gear instead of the nylon and did away with the plastic beads. (The bronze gears just seemed to be better than the stock nylon route. It has been several years ago now and no problems yet!) The bushings are the bearings the headlight pivots on - you'll see them once you get in there.

It was my first foray into the headlight gearing etc. & still was only an hour job start to finish. Bought my repair kit from Mid America Motorworks, IIRC, but if Jerry's Gaskets has the kit, I of course would buy it from Jerry.

[Flyman 27]

I found a supplier with good prices on new motor assemblies and purchased both for around $120.

https://www.carparts.com/details/Chevrolet/Corvette/Replacement/Headlight_Motor/1996/SET-REPC383401.html?TID=gglpla&origin=pla&utm_source=google&utm_medium=pla&utm_campaign=221983653&gclid=Cj0KCQiAn8nuBRCzARIsAJcdIfOh-x8CIBtmpecs0JmclnIWjseM2iON2o_xDtr8Xk1urSu8wb1bmZk aAtvpEALw_wcB&gclsrc=aw.ds

[DRM500RUBYZR-1]

1 out of 10 it is a gear.
9 out of 10 it is the bushings.
Symptom: motors /lights "overrun" either after opening or closing.
We do these every week.
Marty

[DRM500RUBYZR-1]

Yep...stripped nylon gear/drooping headlight. Easy fix for even the novice DIY'er.
I opted for the bronze replacement gear instead of the nylon and did away with the plastic beads. (The bronze gears just seemed to be better than the stock nylon route. It has been several years ago now and no problems yet!) The bushings are the bearings the headlight pivots on - you'll see them once you get in there.

It was my first foray into the headlight gearing etc. & still was only an hour job start to finish. Bought my repair kit from Mid America Motorworks, IIRC, but if Jerry's Gaskets has the kit, I of course would buy it from Jerry.

You may not see them; often they have simply become nylon dust.
Marty

The bronze gear will also solve the problem as would a new motor or a new car.
Try the $10.00 bushings, and spend your money on more fun things.

[XfireZ51]

Just did mine. The bushings were talcum powder.

[dredgeguy]

Had Wazoo do mine a few years ago, the 3 plastic bushings in each were also dust. Got the replacement bushings at Advanced Auto for $7.00 for a package of 3. No need to get anything else.

[DRM500RUBYZR-1]

Just noticed that you have Ruby 180
I am Ruby 181
Marty

[dnobull]

Thanks for everyone's reply. After checking with Marc Haibeck I will get the Bushings. It appears that online they push replacing the gear but the bushings are the actual problem. Haibeck says that the 90-96 Gears never fail so save your money.

Over my two years of a Registry member I have always gotten great information from everyone,

Thanks,

Dave Noble
93 #180

[Young1]

Bushings, Bushings, Bushings. Done it. Plenty of you tubes on it.

[dnobull]

Thank you I got confirmation back from Marc Haibeck on this to save the money because the gears rarely are damaged

[Mystic ZR-1]

Just noticed that you have Ruby 180
I am Ruby 181
Marty

Ruby, don’t take your love ❤️ to town....

[Paul Workman]

Thank you I got confirmation back from Marc Haibeck on this to save the money because the gears rarely are damaged

You'll know when you get in there if they are or not. Missing teeth...is a pretty good indication the gear might(?) be bad. But, that said, my college statistics prof was fond of saying: "ONE example does not a trend make!" So, I certainly yield to Marty and Marc's experience regarding statistical probability (i.e., being the bushing(s) rather than the gears).:)

[ZR2]

So I just replaced my Original plastic headlights that still work and will keep them of course. I know that they are substantially lighter than the Hella Glass H4 conversion set up I bought. Not out at night much but wanted more light just in case. I have read the heavier glass assembly's are hard on the motors. When I was finished I operated my headlights a few times and did hear the motors keep running whether I was putting them up or down. They went on for a few seconds. I guess I should get the bushings so I am ready as I suspect that is the issue?

[ram_g]

So I just replaced my Original plastic headlights that still work and will keep them of course. ... I have read the heavier glass assembly's are hard on the motors. ... I guess I should get the bushings so I am ready as I suspect that is the issue?

Yes. Exact same thing happened to me shortly after I installed the heavier LED units in place of the stock headlamps. It was in fact the bushings.

[ZR2]

Yes. Exact same thing happened to me shortly after I installed the heavier LED units in place of the stock headlamps. It was in fact the bushings.

I don't know that I heard t6he motor continue to run before but I really cant say as I rarely have it out at night and am in the car when I operate them. Feel pretty silly saying that, but am not sure if it was already happening or if it just started with the heavier headlights???? They are going up and staying where they should and closing as they should so maybe I'll just get the bushings and when it is convenient do the bushing replacement. Thanks for the over the internet diagnosis. Mark

[Z51JEFF]

Send it to me,with the parts and I'll repair it provided you pay shipping.

[ZR2]

I appreciate the offer. I can do it, just need to find the time. I have other cars that have more serious pressing issues.

[dredgeguy]

Next time we have a Wazoo get together in Westminster that can be put on our list. Secondchance did mine a few years ago in about 30 minutes. I got the 3 pellets at Advance Auto for about $6. I believe they were in the specialty section and labeled for Ford but were the exact same as what we need or you can always get them from one of the Corvette vendors.