Story Mark Kaufman
Reprinted with permission
Many a C5 owner has heard that unmistakable machine gun sound emanating from the front of the car when turning on the headlights. And if that noise isn’t annoying enough, at least one of the headlights doesn’t come up, or doesn’t go down.
Anyone who has gone through this knows the fix is to replace the factory nylon gear in the headlight motor with a replacement bronze gear.
But what’s up when the gear has been replaced – by a dealer – and it happens again? Certainly the teeth on the bronze gear have not worn down to the point where they disengage from the motor drive gear. When it happened on our subject 2001 convertible, we popped the hood and discovered that epoxy used to hold the gear cover on the motor had failed and fortunately was lying beside it. As a result there was enough play on the gear shaft to allow it to disengage from the drive gear and “rat-a-tat-tat-tat-tat-tat!” each time you tried to use the lights. (more…)