Typically the nylon bushings inside the rotator mechanism have disintegrated. The material used deteriorates over time and use. There are a couple of ways to fix the problem. If you're mechanically inclined, have basic hand tools and are patient, it can be fixed. I had to fix my ZR-1's headlights a few years ago. Ecklers sells a bushing kit. I'll see if I can find the part #. I used steel ***** in mine. I don't recall the diameter though, as these were given to me by a friend.

Here is a great technical article on how to fix this correctly. This is the same article I referred to when I did mine.

http://www.corvettefever.com/howto/33098/

Here is what mine looked like, where the steel ***** go:



[IMG]local://upfiles/1464/0727FB73EFB443B2BD70EE09F011A433.jpg[/IMG]

 

Here's the replacement bushings that I recommend. I used steel ball bearings, but if I had to do it again now, I'd use these Delrin bushings.

http://www.ecklers.com/product.asp?p...dept%5Fid=1476

Follow the instructions here to do the repair.

http://www.corvettefever.com/howto/33098/



[IMG]local://upfiles/1464/A6E7D131A3674B48A9297E04C26F4387.jpg[/IMG]

 

Thanks for info Chris.
I'm still waiting for my 92 to come back from the shop. I had to have the brain,control module,and speed sensor replaced plus some shorting problems. Not excited about getting the bill!!!!!
I'll let you know what I find when I get it back.

 

I just purchased a 85 C-4 with relatively low miles, but unfortunately it has many electrical problems. Is this a common situation? I was told that the headlight motor system had been upgraded to a later style, but it doesn't work either. The instrument cluster intermittently darkens, usually after the car has run for awhile. The readings are still operating only you can't see them at night. unless you use a flashlight. Makes for interesting driving.

 

Unfortunately, probably the only fix for your cluster is to send it in and get it rebuilt as the LED control system within the cluster has problems. Had to have mine rebuilt to the tune of around $500.00 as it had the same problems, cept mine was dim all the time. There is a place in Houston, Texas that rebuilds them for GM. Check with your local GM dealer, they might have a source that rebuilds them.

 

There is a limit switch built in to the motor assembly, it is internal to the headligh motor and does not have any adjustment, it is used to break the electrical connection to the motor once the headlight door has hit its stop.