Headlight motor rebuild - ZR-1 Net Registry Forums

bamawrx · 11-17-2013

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Just completed a power headlight motor rebuild on my 90. Purchased the kit from Mid America, and they only showed a bronze gear for the ‘90. I was concerned because mine had a plastic gear in it, but I figured I’d go for it. After taking the assembly off the car and disassembling the gear housing with the help of the guide from this forum it was time to remove the old destroyed plastic gear. The housing was full of ground up plastic and delrin.

It was a bear to get out the old plastic gear as mine was stuck due to ground up plastic bits. I finally got it all out and cleaned up. Next was to install the new bronze gear with the three new delrin bushings onto the old shaft. It was so tight a fit that I had to press the parts together with my bench vise.

I thought I was going to break something it was so tight, but it went together into a solid unit that dropped right back into the motor housing. I greased her up and reassembled the housing and reinstalled the headlight assembly. She tested out great with rapid up/down with no continued running after reaching full up/down positions.

It was during this test that the drivers side started acting up, and now continues to run after reaching full up/down. Guess its time to order another rebuilt kit! Now it know better how to do the work, so it should be much easier next time. The “how to” on this forum was invaluable. I don’t think I would have attempted the task without it.

bamawrx · 11-18-2013

Here is pic of nice new bronze gear installed...backwards. That was a self correcting error as it turned out.

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Anyone have a specific recommendation on a better headlight? I've looked at the C4 conversion kits that allow for HI bulbs and the Hella European headlights, but its dang near impossible to know what would be brighter. The stock lights are not up to the task.

GOLDCYLON · 11-18-2013

Quote:

Originally Posted by bamawrx

Anyone have a specific recommendation on a better headlight? I've looked at the C4 conversion kits that allow for HI bulbs and the Hella European headlights, but its dang near impossible to know what would be brighter. The stock lights are not up to the task.

I went from sylvania silver stars to Hella H4 housings to HID projectors. To date satisfied. Suggest Hellas with the 120/85 bulbs. Any H4 build will fit those housings.

RICHARD TILL · 11-19-2013

changed mine out to glasss bulbs. gave the plastic away. much more light now.

bamawrx · 11-27-2013

Added Pics.

Franke · 11-27-2013

Good job. No more worries for awhile.

I wonder what is the best kind of grease to use in these motor gears. I have heard of using silicone grease but was wondering what the consensus is.

RICHARD TILL · 11-27-2013

White lithium grease has worked well for me.

11-17-2013	#1
bamawrx Join Date: Jul 2013 Location: Alabama Posts: 59	Headlight motor rebuild ADDED PICS [IMG][/IMG] [IMG][/IMG] [IMG][/IMG] [IMG][/IMG] [IMG][/IMG] [IMG][/IMG] Just completed a power headlight motor rebuild on my 90. Purchased the kit from Mid America, and they only showed a bronze gear for the ‘90. I was concerned because mine had a plastic gear in it, but I figured I’d go for it. After taking the assembly off the car and disassembling the gear housing with the help of the guide from this forum it was time to remove the old destroyed plastic gear. The housing was full of ground up plastic and delrin. It was a bear to get out the old plastic gear as mine was stuck due to ground up plastic bits. I finally got it all out and cleaned up. Next was to install the new bronze gear with the three new delrin bushings onto the old shaft. It was so tight a fit that I had to press the parts together with my bench vise. I thought I was going to break something it was so tight, but it went together into a solid unit that dropped right back into the motor housing. I greased her up and reassembled the housing and reinstalled the headlight assembly. She tested out great with rapid up/down with no continued running after reaching full up/down positions. It was during this test that the drivers side started acting up, and now continues to run after reaching full up/down. Guess its time to order another rebuilt kit! Now it know better how to do the work, so it should be much easier next time. The “how to” on this forum was invaluable. I don’t think I would have attempted the task without it. __________________ 2011 Carbon Edition Z06 #225 1990 ZR1 #88 Last edited by bamawrx; 11-27-2013 at 05:44 PM.

11-18-2013	#2
bamawrx Join Date: Jul 2013 Location: Alabama Posts: 59	Re: Headlight motor rebuild Here is pic of nice new bronze gear installed...backwards. That was a self correcting error as it turned out. [IMG][/IMG] Anyone have a specific recommendation on a better headlight? I've looked at the C4 conversion kits that allow for HI bulbs and the Hella European headlights, but its dang near impossible to know what would be brighter. The stock lights are not up to the task. __________________ 2011 Carbon Edition Z06 #225 1990 ZR1 #88 Last edited by bamawrx; 11-27-2013 at 06:08 PM.

11-19-2013	#4
RICHARD TILL Join Date: Aug 2005 Location: Iuka, Mississippi 38852 Posts: 756	Re: Headlight motor rebuild changed mine out to glasss bulbs. gave the plastic away. much more light now.

11-27-2013	#5
bamawrx Join Date: Jul 2013 Location: Alabama Posts: 59	Re: Headlight motor rebuild Added Pics. __________________ 2011 Carbon Edition Z06 #225 1990 ZR1 #88

11-27-2013	#6
Franke Join Date: May 2013 Location: Beaver, PA Posts: 516	Re: Headlight motor rebuild Good job. No more worries for awhile. I wonder what is the best kind of grease to use in these motor gears. I have heard of using silicone grease but was wondering what the consensus is.

11-27-2013	#7
RICHARD TILL Join Date: Aug 2005 Location: Iuka, Mississippi 38852 Posts: 756	Re: Headlight motor rebuild White lithium grease has worked well for me.