That was some very good information you left there buddy as it's exactly what my problem is. I especially liked Brent Frankers page with all the in-depth explaining of things. I've used his "Fix-it Guide" page many times in the past for my '96 Z28, but I wasn't aware of this particular problem before having never had this type of headlight set-up. The only cars I've ever had with pop-up headlights were the early 80's RX-7's and the '88 Fiero GT's. (They all worked fine though)

So, thank you very much for leaving those links in regards to this common problem with C5 headlight motors. I'll be ordering one of those kits for $45.00 and fixing it myself instead of paying the dealership 200-300 bucks to do it.

 

These forums are a great source of information. Glad to hear it helped.

 

They certainly are, and since I ordered this replacement gear, I figured I should correct the problem that started it. When I bought the car last month, I didn't notice that the driver side headlight door was out of alignment. It wasn't out by much, in fact unless you were looking specifically at the front of the door lid, it was un-noticable. It was actually touching the front bumper cover and sticking as it was closing. After about 30 minutes of adjusting, it now lines up perfectly and operates as it should. Unfortunately the gear is still stripped though so it must be replaced. [&:]