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Maintenance, Mods, & Tips Mods | Tips | Repairs & Troubleshooting

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Unread 06-11-2006, 12:36 AM   #1
pewter99
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Default 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.


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Unread 06-11-2006, 12:43 AM   #2
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How much of a problem is it with the plastic gears stripping?
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Unread 06-11-2006, 12:45 AM   #3
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very common....
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Unread 06-12-2006, 01:30 AM   #4
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there is also a quick fix out there that seems to work well. takes all of 15 minutes. manually raise the headlight and take off the plastic shroud. then reach down and find the nut that holds the linkage and take it off. slide the linkage off the motor, then turn the motor manually again until it has gone 180*. you will then put the linkage back on and tighten the nut. put the shroud back on. lower your light and now you will be using the unused side of the gear. it should last you quite a long time that way. i did this a while back and have had 0 problems with it. after that strips, it will be time for a new gear and the above is the way to go at that point. thanks for the great write up. at least when i do have to change the gear i will know how to do it the easy way. i didnt think of pulling the whole light like that. i was just going to try and get to three bolts with the light on. that looked like a real pain, with the light out it looks 10 times easier.
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Unread 06-12-2006, 01:32 AM   #5
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yep....problem is did you see my gear?? there was no "good" side
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Unread 06-12-2006, 01:39 AM   #6
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yep that one was trashed.
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Unread 06-12-2006, 06:29 AM   #7
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Thanks for the very clear instructions and pictures. Doesn't appear to be nearly as daunting as I had imagined ..............Tom
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Unread 06-12-2006, 09:28 AM   #8
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I did that same repair on a 2000 this past weekend.
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Unread 06-12-2006, 09:48 AM   #9
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Thanks Pewter
Had to do that a few times on the C4s we had but not on the C5s yet.
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Unread 06-12-2006, 10:26 AM   #10
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Quote:
Originally Posted by 2Vettes
Thanks Pewter
Had to do that a few times on the C4s we had but not on the C5s yet.
yeah...with the C5 its not if but when...
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