When Pop-ups Don’t
No, I’m not talking about pop-up advertisements on the Internet. I’m talking about my pop-up headlights. One does, one doesn’t.
I had this problem last year and after a search on www.corvetteforum.com I found a source for metal gears to replace the plastic gears in the headlight assembly. Well, to be honest, my wife found it for me. 
I ordered the replacement parts and updated both headlights. I will post pictures of the cheap plastic gears that GM uses… the passenger side light gear was completely flat on one edge.
The replacement went fairly well, other than during the reassembly I forgot that the lights were mirror images of each other, and I got one of them put together backwards and had to redo it. Everything worked fine when it was all done.
Now the driver’s side light is struggling and failing to pop-up when I turn on the headlights, so my car is in the shop. I took it back to the same place that did my column lock recall, as after some bitching on my part they did the entire repair for free. I figure they have earned some repeat business. As an added bonus they are located very close to my current client so it was easy to drop my car off during lunch and they drove me back to the office.
More details to come…