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.

Bump

Nobody has ever leveled out their pontiac popups?

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

lol i hear ya but just droopy lids would bug me..

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.

Thank you,

Was hoping they could be adjusted/repaired fairly easy so the front of the car would look new again.

Does anybody know of any how-to threads on the subect?

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.

If you have tried this,

I am sorry... I dunno.

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.

How To Adjust Firebird Pop Up Headlights..

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.

Mine droop a little on my 87GTA and they also seem to come down hard like they almost just "drop". In fact they stay up sometimes after I turn them off and shut the car off but always drop down hard within five minutes or so. Is there supposed to be a bumper cushion to soften this up?! I wonder if I need the kit for stripped bushing but I have never been able to verify the motor is spinning and nothing is happening.