My driver's headlight will only pop up once when I reconnect the motor and turn on the light switch, after that it will only make a short clicking sound and not pop up again unless I were to disconnect then reconnect the motor for which then it will open open once again.

The nylon gear and 3 bushings are fairly new as they have been replaced with the rebuild kit.

I just can't figure out why my headllight would only open once and only when I reconnect the motor!!!


Any ideas would be appreciated

 

It seems to me that you've identified your own problem--most likely, that connector is loose/dirty/bad. But I guess the problem could also be inside the motor(not the gear).

Remember Lon's "paper clip trick?" When you reassembled everything, are you sure your wires didn't pop out of place inside the motor? That's just a guess though because I don't know how a motor would react in that situation.

 

I dunno, yes I did the paper clip trick to make sure brushes stayed to the sides but took me a couple tries cuz they kept popping out, Ill have to open them up again and check.

 

But look that connector over real good before you go taking out the motor again. Since you're getting a reaction simply by messing with that connector, it would seem that connector or the wires to it are the problem. Make sure there aren't any loose fitting or frayed wires in the connector or between the motor and the connector.

Also, in case you don't know where it is, your relay is on the firewall behind the master cylinder. It says "GUIDE" on the front of it. I don't think that's your problem though. But in case you don't have any luck anywhere else, you could check the connectors going into it also.

 

It has been a while since I owned a thirdgen with flip up headlights, but here's what I remeber:

There are three relays in the headlight circut. One is on the radiator core support. The other two are attached to each of the headlight motor mechanisms, on the bottom. It sounds like one of them is sticking. When you unplug it, power goes out, the relay opens. But when you reapply power to it, it closes and sticks, so you can't use it again until you unplug it because it is stuck closed. You know what I mean? Look into it, and welcome to the non function firebird headlight door club. You are member number 347,255. Enjoy!