Headlamp and A/C issues (repair and replacement parts questions) - ZR-1 Net Registry Forums

mrmojo1111 · 07-16-2012

I am the new owner of a 1990 red ZR-1, and am in need of some help from the forum. First off, driver's side hedlamp does not fully extend, stops a couple inches short. After reading several posts about common ZR-1 gremlins, I decided I should change out the bushings. Should this solve the problem, or is a more extensive repair likely? What bushings will I need?

Secondly, when I picked up the car yesterday, the po told me that the blower motor resistor needed to be replaced. Does anyone know which resistor I will need? The issue is that the blower motor will continue to run after the car is turned off, and will drain the battery overnight. Currently, I have been pulling the fuse on the blower motor when parked.

Thanks in advance! This is a wondwrful forum, and a big reason I decided to go ahead and buy a ZR-1.

Nick

PhillipsLT5 · 07-16-2012

headlight
http://www.corvettefever.com/howto/33098/index.html

mrmojo1111 · 07-16-2012

Wow! Thanks! I read in another thread that these bushings were available at most auto parts stores. Has anyone found this to be true? The reason I'm asking is that I want to drive her to the NCM in BG this weekend with my dad and his 427 vert 60th. Would like to get this fixed before that trip if possible.

Nick

scottfab · 07-16-2012

Here is a way to do the repair using a washer you fashion yourself.
If nothing else maybe the dimensions are useful when going to a hardware store.
___________________________
Well after reading the recent posts
on the head light repair posts I finally rebuilt one.
I used rubber pieces just to see if Marc H's idea works out.
I like what it does. It definitely dampens the initial movement
so there is no harsh initial jerk. Only problem is it now moves
ever so slightly slower that the other side. Maybe I will do the
other soon to have them match.
The rubber pieces I used were 0.47 X 0.41 in.
I fashioned them using a 0.48 hole punch.
At least that is what it measured but I think it was suppose to be
a 0.475 in. I started with 1/2 in washers with a 9/16 hole in the middle.
They were already 0.41 in think. They were just surplus from another
project.
Any hard rubber would do I would think.

Anyway all went well until I snapped off one of the hex head screws
that holds the motor to the gear.
It would have taken 2hr except for that.

I followed the instructions at:
_http://www.corvettemagazine.com/Body/c4-corvette-headlight-bushing-replacem
ent-1988-1996.html_
(http://www.corvettemagazine.com/Body...1988-1996.html)
Well kinda.
I used a huge short-cut that I'd heard others do.
That is instead of removing the bezel and all I just removed the three torx
bolts that
hold in the motor assembly and took it out. Saves a lot of time but you do
have to
remove a small chunk of metal that keeps you from getting at that 3rd bolt.
It is a corner that had a threaded 1/4 (aprox) hole that was unused.
It is located at the lower left side of the passenger bucket. (hood open)
I guess this car won't be NCRS now.

scottfab · 07-16-2012

For the fan motor running, sure sounds like you have a stuck relay.
Now you just have to locate it. Sure doesn't sound like a "burnt resistor" to me.

gbrtng · 07-17-2012

Quote:

Originally Posted by mrmojo1111

Wow! Thanks! I read in another thread that these bushings were available at most auto parts stores. Has anyone found this to be true? The reason I'm asking is that I want to drive her to the NCM in BG this weekend with my dad and his 427 vert 60th. Would like to get this fixed before that trip if possible.

Nick

Look in the HELP section - there are three white delrin "bushings" in a blister pack - I'm not near the shop so I don't know the part number - the bushing is about 1/2" diameter and maybe 3/8" long. Probably $7.95 ...

mrmojo1111 · 07-17-2012

Quote:

Originally Posted by gbrtng

Look in the HELP section - there are three white delrin "bushings" in a blister pack - I'm not near the shop so I don't know the part number - the bushing is about 1/2" diameter and maybe 3/8" long. Probably $7.95 ...

Forgive me for my "newbie" questions, but what do you mean by "help section"?

Thanks again to everyone for the help and suggestions.

scottfab · 07-17-2012

Quote:

Originally Posted by mrmojo1111

Forgive me for my "newbie" questions, but what do you mean by "help section"?

Thanks again to everyone for the help and suggestions.

"Help" is a line of product from Dorman.
They are carried in most automotive parts stores.
See this link/video
http://www.finddormanhelp.com/

VetteMed · 07-17-2012

Here's the blower resistor module that you may need:

http://www.ebay.com/itm/1993-96-Corv...#ht_800wt_1077

http://www.ebay.com/itm/Corvette-Blo...r#ht_500wt_848

VetteMed · 07-17-2012

Most auto parts stores have a "HELP" section with various knobs, handles, etc.

07-16-2012	#1
mrmojo1111 Join Date: Oct 2011 Location: Springfield, IL Posts: 117	Headlamp and A/C issues (repair and replacement parts questions) I am the new owner of a 1990 red ZR-1, and am in need of some help from the forum. First off, driver's side hedlamp does not fully extend, stops a couple inches short. After reading several posts about common ZR-1 gremlins, I decided I should change out the bushings. Should this solve the problem, or is a more extensive repair likely? What bushings will I need? Secondly, when I picked up the car yesterday, the po told me that the blower motor resistor needed to be replaced. Does anyone know which resistor I will need? The issue is that the blower motor will continue to run after the car is turned off, and will drain the battery overnight. Currently, I have been pulling the fuse on the blower motor when parked. Thanks in advance! This is a wondwrful forum, and a big reason I decided to go ahead and buy a ZR-1. Nick

07-16-2012	#2
PhillipsLT5 Join Date: Aug 2005 Location: Scottsdale, AZ Posts: 2,452	Re: Headlamp and A/C issues (repair and replacement parts questions) headlight http://www.corvettefever.com/howto/33098/index.html

07-16-2012	#3
mrmojo1111 Join Date: Oct 2011 Location: Springfield, IL Posts: 117	Re: Headlamp and A/C issues (repair and replacement parts questions) Wow! Thanks! I read in another thread that these bushings were available at most auto parts stores. Has anyone found this to be true? The reason I'm asking is that I want to drive her to the NCM in BG this weekend with my dad and his 427 vert 60th. Would like to get this fixed before that trip if possible. Nick

07-16-2012	#4
scottfab Join Date: Jan 2009 Location: Portland Oregon metro area (Washington side) Posts: 3,207	Re: Headlamp and A/C issues (repair and replacement parts questions) Here is a way to do the repair using a washer you fashion yourself. If nothing else maybe the dimensions are useful when going to a hardware store. ___________________________ Well after reading the recent posts on the head light repair posts I finally rebuilt one. I used rubber pieces just to see if Marc H's idea works out. I like what it does. It definitely dampens the initial movement so there is no harsh initial jerk. Only problem is it now moves ever so slightly slower that the other side. Maybe I will do the other soon to have them match. The rubber pieces I used were 0.47 X 0.41 in. I fashioned them using a 0.48 hole punch. At least that is what it measured but I think it was suppose to be a 0.475 in. I started with 1/2 in washers with a 9/16 hole in the middle. They were already 0.41 in think. They were just surplus from another project. Any hard rubber would do I would think. Anyway all went well until I snapped off one of the hex head screws that holds the motor to the gear. It would have taken 2hr except for that. I followed the instructions at: _http://www.corvettemagazine.com/Body/c4-corvette-headlight-bushing-replacem ent-1988-1996.html_ (http://www.corvettemagazine.com/Body...1988-1996.html) Well kinda. I used a huge short-cut that I'd heard others do. That is instead of removing the bezel and all I just removed the three torx bolts that hold in the motor assembly and took it out. Saves a lot of time but you do have to remove a small chunk of metal that keeps you from getting at that 3rd bolt. It is a corner that had a threaded 1/4 (aprox) hole that was unused. It is located at the lower left side of the passenger bucket. (hood open) I guess this car won't be NCRS now. __________________ Scott Vett owner since 1979._It's about the car and the people

07-16-2012	#5
scottfab Join Date: Jan 2009 Location: Portland Oregon metro area (Washington side) Posts: 3,207	Re: Headlamp and A/C issues (repair and replacement parts questions) For the fan motor running, sure sounds like you have a stuck relay. Now you just have to locate it. Sure doesn't sound like a "burnt resistor" to me. __________________ Scott Vett owner since 1979._It's about the car and the people

07-17-2012	#9
VetteMed Join Date: Mar 2009 Location: Orlando, FL Posts: 1,828	Re: Headlamp and A/C issues (repair and replacement parts questions) Here's the blower resistor module that you may need: http://www.ebay.com/itm/1993-96-Corv...#ht_800wt_1077 http://www.ebay.com/itm/Corvette-Blo...r#ht_500wt_848 __________________ 2004 Z06/Z16 LeMans Commemorative Edition 1991 ZR-1 #302 White/Gray (sold) 1991 ZR-1 #1147 Red/Saddle (sold)