I searched the forum for a solution to my situation but i did not find what I was looking for.

Here is the problem: The 90' Formula was in an accident about six months ago and after it took 5 months to get it back, I realized the passenger side headlight did not pop up. It came up the first and second time, but then the third time it stayed down. If I manually turn the **** on the headlight motor, the light would come up 2 or 3 times and then stay down. I took out the motor assembley and checked out the nylon ring gear but it was in perfect shape (I already replaced it once). There doesn't seem to be any electrical issues so I am stumped. Any suggestions? Thank you.

 

FYI, it isn't the gear that goes bad on the 1987-92 Firebird headlight motors, but what is inside the gear. Open it up again and clean the gear. Inside you'll fins a triangular-shaped cavity. Inside this cavity were three hard gel cylindrical-shaped bushings. You'll most likely find a spoonfull of off-white chunks. The chunks used to be the bushings. These bushings transfer the load from the gear to a three-lobe cam on the shaft that raises and lowers the headlight bucket. I sell two kits with new Delrin bushings to repair the headlight motor. Click on the TDS (Top-Down Solutions) sponsor link on the right-hand column. ---->

I should clarify my first statement. The first time you repair the headlight motor the bushings is the weak-link, so that is what fails first. Once you've replaced the OEM gel bushings with the Delrin ones the molded nylon gear is now the weak link. I've solved that problem by offering new aftermarket nylon gears and CNC machined aluminum anodized gears.

Download the instructions for the 209280 Deluxe headlight repair kit from the lower right-hand column of my web site under "Documentation" so you know how to properly disassemble and reassemble the headlight motors. There are a few steps that if not done properly will cause the brushes to break on assembly. No fear, I sell those too.

Lon Salgren
Top-Down Solutions