How to adjust(?) the popup headlights on a 95 Firebird?

[Roger]

My headlight motors continue to try to lower the headlights after they are already all of the way down. I assume that there is some sort of an adjustment or sensor/switch that tells them when to stop. As a temp fix I pulled the plugs for the motors with the lights on so that the lights just stay up, but would really like to fix the root problem.

 

[gary o]

Get a repair manual or check for one at your local library. or go to the auto zone web site and check under repairs.

 

[Oreif]

The limit switches inside the headlight motor most likely have dirty contacts.
They work by shifting the drive shaft when it is torqued for the up and down. There are two sets of contacts, One set at the top and one set at the bottom.

Yoy can open the motors and clean the contacts. Some motors have screws some have rivets. If it has rivets, You drill out the old ones and rivet it closed. While they are apart, check the delrin bushings for wear. You can also get some silicone grease and re-lube the gears as well.

 

[Car_Nut]

Head Lights grinding.

The motors actually turn off based on an amp load when the lights shut off, kind of like a circuit breaker that pops when the lights shut down and the motor tries to turn past the stop..

The problem is bad design on Pontiac. They made the gear out of plastic. Over time the gear wears a little and then it just continues to jump the gear. Luckily after a little time it shuts off. Really annoying.

So 4 solutions.

Solution 1: The motor only strips about 1/2 the gear. So, You can disassemble it somewhat and get to the gear - - and turn the gears 180 deg. Then you get about another year or two before it wears out again. Its also a bit tricky to line up perfectly so you might end up going too far and it makes noise when you open them instead of close...

Solution 2: Disassemble - remove the gear - and find an aluminum gear and replace it. (or steel or another plastic.. I'd suggest if you go this far - get a metal gear) (it can be soft, anything better than plastic). - You can even 3d print a gear if you want - I'd impregnate some ball bearings or such into the gear teeth to prevent failure again.

Solution 3: - you can buy the motor kit from auto parts store - its about $140. Replace the whole motor unit. pretty simple but pricy - Sorry, Not sure if replacement motor has good gears in it or not ???? (I doubt it)..

Solution 4: - run the motor wire into the car - add a switch - then when you turn the light on / off - flip the switch to kill the power....

In my opinion - this should have been a recall.