BodyGeneral body information and techniques for repairing, restoring, and modifying your car.
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I have searched everywhere and can not find anything on why some popup headlights sag or how to fix them so they are level with the hood.
I'm going to buy a low mileage 87 bird tomorrow from a dealer who is repairing one light that didnt pop up.
It was perfect when i last saw it but worry it will sag on that side tomorrow when i get there.
Really would like to know what goes wrong and how to repair them as it is sure to be an issue at some point.
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Last edited by GtoRockz; 06-25-2009 at 08:18 PM.
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I believe that they simply need adjusting. There are three (i think) screws that provide minor adjustment but you might need to enlarge the holes. If you think a little droop is bad, try one light high and one way too low (like my car)
Alex
__________________ Ain't nothin' like it, it's a shining machine
Got the feel for the wheel, keep the movin' parts clean ~ Van Halen
The 'sag' or the light doors not lifting all the way up is from the 'bushings' in the drive gear disintegrating over the years.
Lon, from topdown (site sponsor), offers a kit to fix the issue.
If you are talking about body line alignment issues, there are stops in the hosing to prevent the lights from going up or down to far.The housings themselves are adjustable on the radiator support as well.
__________________ "It may look like I'm doing nothing, but I'm actively waiting for my problems to go away."
- '87 Formula Firebird - never ending project
- '91 RS Camaro - beater
- '93 Z28 - donor
- '71 Camaro LT - as if I need another project.....
I am convinced.... Pontiac didn't work very hard on the Firebird pop-up headlight design.
After 10 years of Firebirds in 3rd gen years you would think 5 years through they would have had it right. (I dunno but I bet the 4th gens aren't better)
I have seen imports with flop up lights, and Vettes... that never have a problem.... but I own two 'birds and both lights are jacked.
I know ... i know... it is bushings, or gears, or some crap, truth to be told....
SHOULD be NO PROBLEMS to BEGIN WITH.
*In your case it looks like an adjustment issue.... start loosening screws, and bolts until you can tighten the screw/bolts with the light lid straight with the body/hood.
There weren't any problem when the cars were new. The newest 3rdgen is 17 years old.
Age takes it toll on any mechanical moving part. The fact that the bushings degrade and save the rest of the mechanical workings seems to be a fairly good design. It a simple physical wear item. The motors, relay and related electrical still work (in the case of my 87) 22 years later without fail.
Aside from the consumable (moving) parts, the design is standing the test of time.
So i ordered new nylon headlight gears and bushings from TDS - Thank you TDS for the great service. They came with simple instructions for removing the baskets - 4 10mm bolts. My headlights are now perfectly aligned with the hood and look fantastic, like new. The lights go up and down in perfect time with each other and are very quiet unlike before.. they were clunky before. Now if you do this same job just remember to watch for that tiny little ball bearing at the end of the motor shaft, do not loose it! Its a little smaller than a bb and you must have it when you put it back together.
Now the adjusting part:
Remove the bezel with a Torx driver (four screws) Loosen the two lower backet bolts but keep them finger tight. The two top basket bolts are somewhat adjustable and can be shimmed with a washer if needed. Get it as close as you can with the basket.
Then there are four 10mm bolts that hold the painted tops on to the lights, loosen one at a time and push/pull the corner in the direction need while tightening. If needed you can pull all four bolts and drill them out a little bit for more play.. i used a dremmal with a small grinding stone.
There is also one 10mm stop bolt in each basket that adjust the height when the lights are closed.
Take your time and it will be well worth your effort.
)
