Of the myriad mechanical glitches common to fourth-generation Corvettes, perhaps none is more pervasive-or more annoying-than that of the malfunctioning headlamp motor. Such failures typically can be traced to the construction of the unit itself, which, like so many other parts of the car, seems to have been designed with an emphasis on minimizing costs rather than extending service life.
Fortunately for those of us who have experienced this problem firsthand, the fix is usually both simple and minimally injurious to the budget. When the lamps on our '96 coupe started to fail recently, we conscripted headlamp-rebuilder extraordinaire Rashelle Lovell at Seffner, Florida-based Vette tuner AntiVenom to put things right. The highlights of the repair follow, along with our usual complement of mostly-in-focus photography.
If you've owned a C4 Vette...
If you've owned a C4 Vette for long, you've most likely encountered problems with one or both of your car's electrically operated headlamp motors. Signs of an ailing motor include a lamp that fails to open or close, opens or closes only partway, or makes a loud popping sound while in motion. Even if only one lamp is exhibiting problems, it makes sense to fix both of them while you're at it.
AntiVenom's unofficial chief...
AntiVenom's unofficial chief headlamp technician Rashelle Lovell begins the repair by removing the bolts that hold the headlamp assembly in place.
With that done, the entire...
With that done, the entire lamp assembly is removed from the car and placed on a workbench for easy access.
Next, Lovell removes the bolts...
Next, Lovell removes the bolts that secure the motor to the lamp. The lamp assembly can then be set aside for the remainder of the job.
The next step is to remove...
The next step is to remove the cover from the motor housing, exposing the plastic gear inside.
The gear is then removed from...
The gear is then removed from the housing and separated from the shaft. If your headlamp motors have never been repaired, chances are the gear will look something like this. The crumbly mess in the center section is what's left of a factory-installed hard gel that once actuated the gear. Is it any wonder our lamps weren't working properly?
To forestall future futzing,...
To forestall future futzing, Eckler's provided us with two sets of heavy-duty Delrin motor bushings (one for each motor). Unlike the factory setup, these bushings are designed to last the life of your car. Even better, they cost only $5.99 per side.
Next, Lovell inspects our...
Next, Lovell inspects our stock headlamp gears for damage. Finding none, she cleans the remnants of gel from the threads to ensure that they interface cleanly with the ones on the motor.