Floppy DS headlight - ZR-1 Net Registry Forums

Don in VT · 07-24-2010

Hi All,

First issue with Cherry's 1990 ZR. The old floppy headlight. Had that problem with my Fiero GT. In fact the motor looks just the same.

Is the Corvette Central kit the best choice ? How about a supplier that is in the brotherhood ?

Recommendations anyone

Don

Coupe89 · 07-24-2010

Change out the 3 bushing in the motor.
I did this to my 89 Vettte and 90 Firebird.

Just hard plastic white spacers. File them down to fit
I pick mine up from the local hardware store. For ~$3 a pair.

RICHARD TILL · 07-25-2010

1/2" diameter & 1/2" length will work just fine if you decide to make them yourself.

USAFPILOT · 07-25-2010

I just replaced the gear and bushings with the kit from mid america on my Z. I did both sides but only had one acting up. The problem headlight had no bushing left when I removed them; they had turned into dust! The other was fine but I replaced it anyway and upgraded to the brass gears instead of nylon. The bushings in the kit are solid vs the original hollow cylinders. They were a little too big but I just mashed them in with a vice...I hope that was ok. Time will tell I guess. When you do it you do NOT need to open up the Motor housing, just the gear housing. The kit has you take apart the motor and remove the worm gear for no reason. It is a pita and unnecessary. Just open up the gear housing and replace the bushings, and the gear if you want to. My nylon gears were worn but looked like they would still last a while. I ordered the brass gears because I thought the teeth were stripped, but they weren't. The problem headlight nylon gear may fave been flexing without good busing in there causing the teeth to slip, but with good bushings it may have been ok. I guess by doing the brass gears I hopefully get a solution that is more durable, who knows? At least the headlight go up and down now and don't jiggle or flop.

phrogs · 07-26-2010

I had to do this on a few C4s nothing to hard but I didn't fall into the BS about the brass gears just get the bushings from whoever has the cheapest price.

PhillipsLT5 · 07-27-2010

I got the cheap plastic parts, did both sides, all is OK, normal C4 stuff, old bushings looked like parm cheese, correct do not open up motor, remove entire housing from car to work on it, you can adjust worm gear without removing it to get it put together then readjust worm

Aurora40 · 07-27-2010

FYI, I believe the motors are the same as used on the Fiero (and Lotus Elan actually). If you've done the bushing swap on one of those, this'll be the same.

07-24-2010	#1
Don in VT Join Date: Jul 2010 Location: Fairfax, VT Posts: 203	Floppy DS headlight Hi All, First issue with Cherry's 1990 ZR. The old floppy headlight. Had that problem with my Fiero GT. In fact the motor looks just the same. Is the Corvette Central kit the best choice ? How about a supplier that is in the brotherhood ? Recommendations anyone Don

07-24-2010	#2
Coupe89 Join Date: Aug 2009 Location: Livermore, Ca Posts: 204	Re: Floppy DS headlight Change out the 3 bushing in the motor. I did this to my 89 Vettte and 90 Firebird. Just hard plastic white spacers. File them down to fit I pick mine up from the local hardware store. For ~$3 a pair.

07-25-2010	#3
RICHARD TILL Join Date: Aug 2005 Location: Iuka, Mississippi 38852 Posts: 756	Re: Floppy DS headlight 1/2" diameter & 1/2" length will work just fine if you decide to make them yourself.

07-25-2010	#4
USAFPILOT Join Date: Aug 2007 Location: Spring TX Posts: 1,348	Re: Floppy DS headlight I just replaced the gear and bushings with the kit from mid america on my Z. I did both sides but only had one acting up. The problem headlight had no bushing left when I removed them; they had turned into dust! The other was fine but I replaced it anyway and upgraded to the brass gears instead of nylon. The bushings in the kit are solid vs the original hollow cylinders. They were a little too big but I just mashed them in with a vice...I hope that was ok. Time will tell I guess. When you do it you do NOT need to open up the Motor housing, just the gear housing. The kit has you take apart the motor and remove the worm gear for no reason. It is a pita and unnecessary. Just open up the gear housing and replace the bushings, and the gear if you want to. My nylon gears were worn but looked like they would still last a while. I ordered the brass gears because I thought the teeth were stripped, but they weren't. The problem headlight nylon gear may fave been flexing without good busing in there causing the teeth to slip, but with good bushings it may have been ok. I guess by doing the brass gears I hopefully get a solution that is more durable, who knows? At least the headlight go up and down now and don't jiggle or flop. Last edited by USAFPILOT; 07-25-2010 at 04:01 AM.

07-26-2010	#5
phrogs Join Date: Jul 2004 Location: Kalamazoo MI Posts: 1,753	Re: Floppy DS headlight I had to do this on a few C4s nothing to hard but I didn't fall into the BS about the brass gears just get the bushings from whoever has the cheapest price. __________________ JOHNNY P Currently own 90 ZR-1 #845 DRM 500 engine package 90 #226 Parts car Hit me up if you need anything.

07-27-2010	#6
PhillipsLT5 Join Date: Aug 2005 Location: Scottsdale, AZ Posts: 2,452	Re: Floppy DS headlight I got the cheap plastic parts, did both sides, all is OK, normal C4 stuff, old bushings looked like parm cheese, correct do not open up motor, remove entire housing from car to work on it, you can adjust worm gear without removing it to get it put together then readjust worm

07-27-2010	#7
Aurora40 Join Date: May 2005 Location: Leesburg, VA Posts: 2,713	Re: Floppy DS headlight FYI, I believe the motors are the same as used on the Fiero (and Lotus Elan actually). If you've done the bushing swap on one of those, this'll be the same. __________________ Bob Saveland Former owner of #2517 [IMG]http://a.random-image.net/aurora40/vette.jpg[/img]