Newly redesigned for improved longevity! This kit has been redesigned and re-engineered for the 1993-1997 Firebird, 1998-2002 Firebird and late style (Late 2000-2004) C5 Corvette plastic housing motors. Now upgraded to include a newly engineered steel support brace with a special plastic bushing. I have noticed a few glue joint failures in these plastic housing motors. Glue joint failures happen because the plastic housing of the headlight motors 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. For these headlight gear repair kits I have added a special stamped steel support brace with a plastic bushing. The brace and bushing does two things. It applies a slight pressure against the side cover to help eliminate side cover glue failures. Most importantly it adds a new bearing surface to support the shaft. This removes all the pressure of the shaft from the side cover by transferring it to this new brace. Once installed this repair should easily last the life of the car. The early (97-99 and some early 2000) Corvettes have an aluminum housing and do not need this special brace. Those headlight motor assemblies are very heavy duty and only require a new gear.

If your headlight actuation unit makes a grinding noise when turned on or turned off (usually this will happen at the full open or full closed position) this is the classic symptom of a bad headlight gear. This kit will repair your headlight motor. If you do not repair or replace your headlight actuation unit once this begins to happen, very soon the headlight will fail to rise at all. If your car has the factory alarm/remote door locks the headlights may act funny if you have a headlight actuation unit that is in need of repair.

In most of the Firebirds and Corvettes with a plastic gear, by the time the gear has failed the OEM black rubber bumper inside the gear is also in poor condition and should be replaced. This kit includes an aftermarket rubber gear bumper that is molded of a tougher rubber than OEM.

The OEM plastic gear and the rubber bumper are the weak parts in these headlight actuation units. Once rebuilt with the new heavy duty CNC brass gear and aftermarket rubber bumper the headlight actuation unit will be better than new and should last the life of your car.

Kit Contents: CNC machined brass headlight gear, aftermarket rubber gear bumper, T-shaped housing brace with plastic bushing and washer, packet of synthetic grease, urethane packet, mixing stick, installation instructions. One kit repairs one headlight actuation unit.

NOTE: There are differences in the headlight actuator units used on the 1997-04 (aka C5) Corvettes. These 1997-99 Corvette motor assemblies have an aluminum case with a removable side cover held on with 3 screws. The 1993-97 Firebird, 1998-2002 Firebird and 2000-04 Corvette motor assembly has plastic case. For this style motor the case needs to be pried apart at the factory glue joint to replace the worn gear. To be sure you order the correct kit you need to verify if your headlight actuation units are plastic or aluminum. The aluminum housing was used on the 1997-99 C5 Corvette. It has 3 screws holding the side cover on. This kit is designed to repair the molded plastic style of headlight actuation unit, for the applications previously described. There may be a rare instance where someone swapped in an older style (aluminum case) 1997-99 motor assembly into your Corvette. That style was discontinued by GM. If your headlight actuator unit has an aluminum case, order TDS 509210, 1997-99 Corvette C5 Brass Headlight Gear & Bumper Kit.