1997-2004  C5 Corvette

Replacement Headlight Gears

1997 1998 1999 2000 2001 2002 2003. Corvette  Headlight gears noise wink grinding brass GM headlight motor flap cover light bright broken clanking spinning Vette Headlight Gear Kits Corvette Headlight Kits Corvette Headlights Vette Headlight Corvette Headlight motor Vette Headlight motors Corvette Headlight motors VEtte Headlight motor Chevrolet Headlight motors Vette Headlight fix Corvette  Headlight parts Vette Headlight Gear Kits Trans Am Headlight Gear Trans Am Headlight Gears Firebird Headlight Firebird 

NEW from Rodney Dickman

*Each brass headlight gear now includes a new heavy duty rubber bumper

These new CNC machine made brass gears and new heavy duty rubber bumpers are made to replace the failure prone plastic headlight gears and rubber bumpers used in the 1997-2004 C5 Corvette headlight motors. If your 1997-2004 Corvette headlight motor(s) run but do not properly open or close, or your headlight motor(s) make an awful racket once fully open or fully closed, this product is for you.

Fits Firebird 2002-93, Corvette 2004-97 and Saturn SC Coupe 1996-91. Replaces damaged gear inside motor.
OEM#'s: 16516653, 16516654, 16524229, 16524230


Precision CNC machining ensures an exact match and perfect fit.

New brass gear and new rubber bumper installed in a C5 headlight motor.

 Why buy a fragile new $150+ headlight motor when you can make your existing headlight motors heavy duty with this new brass gear and new heavy duty rubber bumper.

Note: When I first started selling these new brass gears for the C5 Corvette headlight motors I received feedback from some C5 owners stating that some of the OEM rubber bumpers were found to be in very poor condition or showed some level of degradation. At the same time many of these OEM rubber bumpers still appeared to be in good condition.  This made it necessary for me to have the rubber bumpers reproduced.  Even if the OEM rubber bumper inside the original gear appears to be in good condition I feel it may not last the life of the new brass gear. I have had these rubber bumpers reproduced in a tougher rubber that should last the life of the motor. I now include one of these new rubber bumpers with each C5 headlight gear ordered.

Complete detailed step by step instructions are included with each gear.  This is an easy repair most C5 owners can do themselves.  Rebuilding the headlight motor is a fairly easy task.  It is harder to take the headlight motor out of the car then it is to rebuild them

* A packet of silicone grease is included with each new gear kit.  This silicone grease will never dry out like conventional grease.  The 1997-1999 gear kit also includes a new side cover gasket.  The side cover is held on with three screws.  The 2000-2004 gear kit includes a packet of urethane glue that is necessary to re-seal the side cover and a new steel side-cover brace.  The side cover is glued on but it is easy to open to do the repair.

Late 2000+ Kits are NEW and IMPROVED

Now upgraded to include a newly engineered special steel brace with a special plastic support bushing for the late 2000-2004 type plastic housings. I have noticed a few glue joint failures. Glue joint failures happen because the plastic that these headlight motors are made of does not take any adhesive well. The glue joint surface is small and once installed it has to take a tremendous force that occurs when the headlight gets full open and full closed and stops abruptly. I have added a special stamped steel brace with a special plastic bushing. This brace and bushing does two things. It applies a slight pressure against the side cover helping to eliminate side cover glue failures. But most importantly it adds a new bearing surface to support the shaft thus removing all the pressure of the shaft from the side cover and transferring it to this new brace. Once installed this repair should easily last the life of the car.

Why rebuild your headlight motor with a cheap plastic gear that will not last, and also, why risk having a glue joint failure? My brass gear ensures the actuator motor will last and the glue joint will not fail.

NOTE #1: There are 2 variations of the headlight actuator motor assemblies used on the 1997 and up C5 Corvettes. The 97-99 motor assembly (and some early 2000 models) is all aluminum and has a removable side cover that is held on with 3 machine screws. The gear kit for the 97-99 motor assembly includes a new side cover gasket. The late 2000+ motor assembly is partially plastic has a glued on plastic side cover. This cover needs to be pried off (broken at the factory glue joint) to replace the worn gear. The cover is easy to pry off and I include a packet of urethane glue to reglue it back on. Included with each replacement gear is a packet of silicone grease that will never dry out like the grease used by the original manufacturer. Also included: Complete detailed rebuilding instructions and how to remove the headlight motor assembly from the car.

NOTE #2: If you have a 97-99 C5 Corvette there is the possibility that one or both of the early aluminum type headlight motor(s) have been replaced with the newer 2000+ style plastic type headlight motor(s). To ensure you receive the correct kit please check to see if the headlight motor(s) in your 97-99 (and early 2000) C5 are plastic or aluminum. The aluminum housing style is the original equipment used on the 97-99 (and some early 2000) C5 Corvettes. They will have 3 screws holding the side cover one while the 2000+ headlight motor assemblies are plastic and the side cover is glued on. This newer style headlight motor change can occur because the 97-99 style motors are no longer available through GM. If a previous owner or a GM dealer has replaced a headlight motor in a 97-99 they may have installed the newer 2000+ style. A quick check will ensure that you order the correct rebuild kit.

If you are not sure which style motor you have look at the pictures below.

The early aluminum housing type motor assembly is on the left and the late plastic type motor assembly is on the right.


Upgrade your older brass headlight gear kits with the new steel brace and better urethane adhesive.

Fits Firebird 2002-93, Corvette 2004-97 and Saturn SC Coupe 1996-91. Replaces damaged gear inside motor.
OEM#'s: 16516653, 16516654, 16524229, 16524230.

 Price is only

$43 each Or $85 for two 1997-early 2000 kits

$43.95or $87 for two late 2000+ C5 kits

Add  $6 shipping for one or $7 for two.

* WI residents please add  5% sales tax.  $2.30 for one or $4.15 for two.



To order, 

E-Mail me at:    rodney1@execpc.com

OR order online on my  www.rodneydickman.com Fiero site.

Just click on the "Fiero" page link, and then look in the "Electrical" section.

Or Call:

Rodney Dickman's Vehicle Accessories.  (262) 835-9575

Or Send Check or Money Order to:

Rodney Dickman

7604 Treeview Drive

Caledonia, WI. 53108

*Checks may delay shipping by 7-10 days, or until the check clears the bank.  Money Orders ship immediately.

Q: Why does the headlight motor of my 1997-2004 Vette keep running after I turn the lights off? What's that strange buzzing?

A: There is a little plastic gear that has probably stripped out inside the headlight mechanism. This gear is replaced with my Brass Replacement Headlight Gears.  This is an easy repair most C5 owners can do themselves.

1. Manually crank malfunctioning headlamp to the full up position, or turn headlights on if they will raise on their own.
2. Remove black plastic shroud around headlamp to gain easier access to bolts for motor.
3. Remove motor assembly.   It is held on by 3 bolts. .
4. Take the motor to the work bench and remove the screws holding the cover. Or, depending on year, carefully pry off the cover from the gear box. 
5. Once the cover is off, you will see a nylon gear about 2 inches in diameter. There should be a spot on it where the teeth are damaged or ground off from the metal gear that meshes with it. This is where the problem resides. GM used a plastic gear, that can't stand up to the rigors of daily use. 
6. With the side cover removed,  simply pull the old gear and shaft out of the motor and pull the old gear and bumper off the shaft. Install the new brass gear and new rubber bumper on to the shaft and put it back in the motor housing. There are no tools required to do this step. All the parts slip together.
7.  Screw cover back in place, or use some epoxy glue (included) to glue the cover back on. Re-install the motor in the reverse order.



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Copyright 2003. Rodney Dickman's Vehicle Accesories. Caledonia, WI.