Headlight Door Question
 

Although it's not confirmed at the moment, from what my godson Clint is telling me we will be doing a headlight door gear replacement within the next week on his '90 ZR-1. An online search suggests we have three choices for gear material: plastic, brass and aluminum. I am leaning toward brass because it is probably more durable than plastic, but aluminum gears are somewhat less expensive than brass. Any thoughts, suggestions would be greatly appreciated.

Re: Headlight Door Question
 

Is the headlight rotating mechanism malfunctioning leading to an assumption that the gear needs to be replaced? Or, have you disassembled the assembly and noticed the gear was damaged? Reason I'm asking is that, from what I have seen over the years, it's the delrin bushing that typically fail.

Re: Headlight Door Question
 

Thanks for the reply. As I said, the need for gear replacement has not yet been confirmed, and I'm well aware of the typical Delrin bushing failure. In any event, though, I want to be prepared by having the appropriate parts on hand to complete the job expeditiously. What I'm really asking is if anyone has experience or opinion about the use of an aluminum gear rather than a brass one.

Re: Headlight Door Question
 

Opinion: use the existing delrin gears and rotate them so a new tooth area engages the drive gear - YMMV. Not opinion - I have never used a metal replacement gear.

Re: Headlight Door Question
 

Hey Yun, I've got the same problem. Cause is not yet confirmed but the symptoms are:
- Bucket opens/closes effectively
- No issue when bucket goes closed to open positon
- When going from open to closed however, the bucket closes properly but the motor continues to run (as evident by an audible clicking sounding as if the plactic gears are rotating past a hard stop)

The fact that it effectively opens and closes leads me to believe the grear is fine (unless I continue to let it run "past stop" for too much longer) and it's probably the delrin bushing. Thoughts?

Hope this helps GSJoe...

Re: Headlight Door Question
 

Your description leads me to suspect gear issue. Delrins, when they fail, literally crumbles. At this point, headlight will not open fully (based on what I have seen so far). Your situation may be excessive clearance between the gear and the pinion (there is a lash adjustment) or partial rotation of gear or gear replacement.
As for aluminum vs. brass, can't say one way or another - never tried either.

Re: Headlight Door Question
 

You've got more experience than I with this anomoly. I'll get a gear. I can think of advantages/disadvantages for either plastic, aluminm, or brass. If it were you, what would you go with?

Re: Headlight Door Question
 

Never heard of the aluminum wheel as an option. Just Brass which is appealing as it replaces the factory plastic gear. I believe its a while you are there type of mod after replacing the delrans bushings that have prob turned to dust. Only advantage of metal is less wear and a weight savings in the aluminum vs. the brass. Ive never heard of a gear failing although as it always tends to be the Delran bushings.

Re: Headlight Door Question
 

If i was replacing mine I would choose brass simply because plastic piece being sold may be made out of poor quality plastic (oem plastic gears are fine after 150,000 miles and 21 years of use). Brass gears have been around for quite a few years. Aluminum? This is the first time I heard of these gears being available in aluminum.
Chances are that plastic OEM gear can be reused.

Re: Headlight Door Question
 

It seems the aluminum headlight motor gear is unknown to several posters in this thread. Perhaps it's a new item. Anyway, here's a link to a kit containing two aluminum gears, the Derlin bushings and several other pieces. As I said above, the aluminum gears can be had for less money than those made of brass. I just don't know if they are in any way inferior to the brass ones. http://www.ebay.com/itm/Corvette-Fie...9f469a&vxp=mtr