How to change the headlight motor gear in a C4 Corvette

How to fix C4 Corvette Headlights that wont go up or down. This video will show you how to take off the headlight assembly, take off the headlight motor, and change out your worn gear with a nice new one

If your headlights are not going up, or it goes up but easily falls back down, this is what you need to do to fix it.

Plastic gear and bushings (good price and all you need):
Bronze gear and bushings:

This is really easy to do and it will save you a lot of money. The dealer wanted $400 per light. This takes an hour each light if you take your time!

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Disclaimer:
Due to factors beyond the control of ChrisFix, I cannot guarantee against improper use or unauthorized modifications of this information. ChrisFix assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this information at your own risk. ChrisFix recommends safe practices when working on vehicles and or with tools seen or implied in this video. Due to factors beyond the control of ChrisFix, no information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not ChrisFix.

[bryceyoungberg]

Just want to state for the record, I just bought my first C4 corvette. And 12 years later, Chris fix is still helping me out

[talapeanutbutter]

I watched other videos but found yours to be the most complete. I have a ‘90 which would work sometimes but not always. I had lots of practice from a ‘98 Firebird. So fairly the same. The c4 gear and bushings were fine. The gear itself was cracked all the way through the teeth. Someone had taken it a part and just rotated the gear to put the crack on the other side where it wouldn’t be used. It’s a temporary fix and works but one can never tell for how long. I figured it I’m taking it out and apart, it’s getting a new gear and bearings! Thanks again! BTW…anyone can do this fix! I’m an older woman who jumps in and gets things done!

[TizonaAmanthia]

almost SIX years ago, and you'd already gotten the spread of tools needed, your channel developed pretty fast! kinda binge watching all your old videos, I'm looking foreward to that first mention of soapy wooder

[chrisfix]

Thanks a lot!!!! It is great to get feedback (good and bad) and when the feedback is this kind it makes creating these videos all worth I am actually just a backyard mechanic learning as things break. I figure that it's helpful for others to learn how to fix stuff so they can try it for themselves. And what better way to learn then watching someone do it and following along!

[moizsiddikio]

Chris your corvette (red)is the most beautiful I have ever seen!

[chrisfix]

The opti isnt a problem on the 96 Vettes. It is vented! I got mine soaked in antifreeze when the waterpump went, and it is still running great (original too)... Glad the video helped!!!

[chrisfix]

It is a little different for the 84 I think, but the same basic idea applies. Good luck with the fix, its pretty easy!

[tedvlahopoulos]

Used this video to replace the gears on my 1995 Corvette. Worked well. The hardest part was removing the pins, the rest was a breeze! Thank Chris!!!!

[stephengreene]

Dude, you are awesome!  I bought a 1995 last Friday, the 4th.  Lights shuddered when opening or closing.  I watched your video this past week, bought the gear and bearings and installed them today.  I couldn't have done it without your video!  The drivers' side took me about 2 hours but the second only about 45 minutes!  That's simply because I knew what I was doing by the time I got to the second one, lol.  One suggestion as a tip, remove the headlight cowling before you do anything.  Number one, it helps prevent scratches to it and, number two, it makes easier access to one of the bolts on the motor assembly.  Plus, you might as well replace the headlights once you pull the whole assembly out.  Mine were probably original headlights since the car has just 30, 300 miles on it.  Thank you so much again, Chris!!!

[atgordon]

Chris, you have done a good job on explaining the basic ideas, but
1. Remove the outer painted light cover before you start ... rotate the housing manually so it is open about 1/4 of the way, 2 Phillips screws on the outside, and 2 T1 torx on the inside, and you avoid any damage to the paint work!
2. Never hammer a drill bit into a roll pin ... drills are hard (HSS or high carbon steel ... quite brittle), use a 1/8" drift or a blunt nail (hammer the end to flatten it down). If the drill breaks in the hole, it is VERY difficult to remove, and you are going to junk the housing ($$).
3. It is a lot easier to remove the roll pin while the housing is in the car ... you avoid the blocks of wood and things falling over problems. Prior to removing the light housing, rotate the light so you can see the roll pin and use a small drift or a long penny nail and tap the roll pin through the arm.

[chrisfix]

Glad it helped! Yea, I am on the Corvette Forum and a few of the other smaller Vette forums... Good Luck changing the gears! It is an easy job, just take your time!

[lsasser]

Just fixed both of my C4 headlights today, thanks to your video. I had it playing on my work table as I completed the repairs. Passenger motor is just a little different, but not hard to figure out. Thanks for the excellent tutorial.

[chrisfix]

Thanks man. It's weird because most of my videos, even ones that are so simple that there is no fathomable reason for a dislike, I get them... The key is having significantly more people like the video (that is where I think I do pretty good)

[toddeveretts]

I know this is several years old now, but I smiled the whole way though watching a young guy fix this with the tools he had. Loved the carpenters hammer, towel on the ground and just doing it. Well done Sir. Loved the vid

[DSalter]

Thank you so much for the terrific video lesson! Using your guidance, I changed the gears / bushings on both headlights of my '88 Corvette this weekend and they now work perfectly. The old bushings had, amazingly, disintegrated completely into a fine powder. The only minor “problem” I encountered during the repair was that the new bushings were a little too large and had to be sanded down slightly to fit.

[mr.doctorprofessorpatrick]

getting a c4 corvette coming in tomorrow, rewatching these videos to get into the zone of repairing it!

[mcsaripkin]

I have a 1990 that I bought cheap. A few repairs needed. Headlight is one. This video will be very useful. Your "how to remove the battery" was also very useful. You are my Corvette genius.

[danielwindecker]

I love how you started out just wanting to help people learn to fix things on their own and now even though your channel has grown like a wildfire you’re still just wanting to show people how with just a little effort they can fix their car too. Good for you!

[toddekstrom]

Great video. Just wanted to clarify that my 1986 was different in many ways. But you showing that the gear was changeable was all I needed. You saved me some bucks by posting that video. Thanks!

[flyboy]

Hi Chris, thanks for the video! Just repaired my '89. On mine the gear was fine, only the bushings needed replacing... Works like a charm now and I have a spare gear for when I have to do the passenger side.