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Don't know if this has been covered so well. Posted it my forum, but figured it's really better suited here.
Does your firebird make super loud grinding noises when you turn the headlights on or off? Sounds like the motor continues to run after the headlights are already in the fully up or down position? Did the dealer or repair shop tell you that you had to buy a new headlight motor and pay out the nose? Well worry no longer! Use this walk through! The problem has nothing to do with the headlight motor. The motor assembly contains a large plastic gear that has stripped down and broken. You can buy only the gear separately and replace it yourself very easily! Costing only a small fraction of what the entire motor assembly would cost! So let's begin shall we?
First, you will need to buy a new gear for each headlight that has problems. They are universal, so they work for either side. You might think about doing both motors now while you're at it, vice fixing one and the other one crapping out soon after. Although I don't think GM sells the gears separately, they can be found all over online. I bought mine off Ebay. Here's a link to some
Directly on the sides of each headlight, you can easily find and get to the headlight motor assembly. The rubber cover has been removed in the picture. Turn your headlights on, disconnect the motor (light blue arrow below) and then turn the headlights off. Now, use a Phillips screw driver to take off the plastic covering around the headlight itself. 4 screws. It's may be hard to squeeze it out from around the headlight, but pull it out and set it aside.
Then, use a socket wrench to unbolt the headlight linkage from the motor assembly. (Green arrow is pointing to it) Pull the linkage off the drive rod. It's not easily at all, but it does just pull straight off. I used a large crow bar to gently break it free. Now the headlight is free from the motor. Doing this in the beginning gives you easier access to the remaining bolts. Prop the headlight in the up position with something. Unscrew the 3 bolts holding the motor assembly in place. (yellow arrows) Use a crescent wrench to hold the nut in place and a socket wrench to unscrew the bolts. There's not much room to move around down there is there? Glad you removed the linkage first huh?
Use a flathead screwdriver to gently pry off the back cover. It's on there pretty good. Stick the screwdriver in as far as you can and twist. It should start breaking free.
This is what you'll see. Pull the large white plastic gear out and inspect it closely. I bet it'll look like this:
Notice the missing tooth on both gears. And the teeth directly above the missing one are severely damaged
\/\/\/\/Continued below\/\/\/\/
Does your firebird make super loud grinding noises when you turn the headlights on or off? Sounds like the motor continues to run after the headlights are already in the fully up or down position? Did the dealer or repair shop tell you that you had to buy a new headlight motor and pay out the nose? Well worry no longer! Use this walk through! The problem has nothing to do with the headlight motor. The motor assembly contains a large plastic gear that has stripped down and broken. You can buy only the gear separately and replace it yourself very easily! Costing only a small fraction of what the entire motor assembly would cost! So let's begin shall we?
First, you will need to buy a new gear for each headlight that has problems. They are universal, so they work for either side. You might think about doing both motors now while you're at it, vice fixing one and the other one crapping out soon after. Although I don't think GM sells the gears separately, they can be found all over online. I bought mine off Ebay. Here's a link to some
Directly on the sides of each headlight, you can easily find and get to the headlight motor assembly. The rubber cover has been removed in the picture. Turn your headlights on, disconnect the motor (light blue arrow below) and then turn the headlights off. Now, use a Phillips screw driver to take off the plastic covering around the headlight itself. 4 screws. It's may be hard to squeeze it out from around the headlight, but pull it out and set it aside.
Then, use a socket wrench to unbolt the headlight linkage from the motor assembly. (Green arrow is pointing to it) Pull the linkage off the drive rod. It's not easily at all, but it does just pull straight off. I used a large crow bar to gently break it free. Now the headlight is free from the motor. Doing this in the beginning gives you easier access to the remaining bolts. Prop the headlight in the up position with something. Unscrew the 3 bolts holding the motor assembly in place. (yellow arrows) Use a crescent wrench to hold the nut in place and a socket wrench to unscrew the bolts. There's not much room to move around down there is there? Glad you removed the linkage first huh?
Use a flathead screwdriver to gently pry off the back cover. It's on there pretty good. Stick the screwdriver in as far as you can and twist. It should start breaking free.
This is what you'll see. Pull the large white plastic gear out and inspect it closely. I bet it'll look like this:
Notice the missing tooth on both gears. And the teeth directly above the missing one are severely damaged
\/\/\/\/Continued below\/\/\/\/
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