**** C5 Headlight Gear replacement***

Parts needed:

brass gear kit
10mm socket
13mm socket
1/4 drive ratchet
magnetic pick-up tool
phillips screwdriver

brass gear kit (you can get this from Rodney Dickman) at www.rodneydickman.com (yes I know he sells Fiero parts...trust me he sells the gears for the headlight) you can order online or call him. he is a super nice guy and ships the stuff Priority Mail.
you can also buy the kit thru MidAmerica.


Ok, lets get started. Turn the headlights on or manually crank up the bad light. If you turned the lights on you can unplug the bad light and turn the other light off so as not to kill the battery.

Remove the black plastic headlight surround, 3 Phillips head screws. Now look inside the opening and you will see there are basically 5 nuts/bolts that hold the assembly in place. the following pics show the locations.




After these bolts /nuts are removed lift the assembly out and you have this.



Turn the whole piece on its side and you will see the round cover which is secured with 3 little screws:



Remove these screws and take off the cover. You will probably see something that looks like this.






Make note of how you remove things and clean all that stuff out of there so it will look like this.





Now install the new gears and replace the cover.



Install is the reverse of removal. Plug everything back in and you should have this.

Nice "how to" .

Joe B.

98 softtail said:

Nice "how to" .

Joe B.

Click to expand...

Thanks.....usually try to take pics to help everyone else out.

awesome! my Vette has been giving me issues with the lights not popping up

What kind of lube do you use with the new brass gear? Great writeup.:dancer01:

C5 headlight replacement

Pewer99,
Thanks a million for your most excellent photo instruction. I was trying to remove the H/L motor by trying to access the three bolts and nuts that hold it on. Not the best of methods. I thank you again for taking the time to photograph the steps required to make a difficult much easier. Also, is it possible to electrically bench check the H/L door open/close cycle in addition to turning the manual knob on the motor. It would be a shame to reinstall the H/L assembly only to discover that there is still a problem.
Thanks again,
Chuckie:dancer01:

Nice job on your how to:thumbsup: