Ok, I'm working on my mom's 02 Firebird this weekend, and everytime you fix the headlight, it works for maybe a dozen times and then stops. After that it works if you manually put it up a little bit, but when it goes down again it's gone. I'm relatively sure it's got something to do with the tab that should stop it in the up position, as it is bent i, and when you bend it back out it gets bent back pretty quickly. Then it goes past the limit to where it should be and doesn't work anymore. Anybody else have this problem? If so, any solutions?

 

The stop tab on mine broke off so I designed a replacement part and it bolts right on with the headlight motor bolts. Works Great! I saved the sketch and dimensions incase someone else needed it. I'll post it when I get home.

 

Thanks, that would help a lot.

 

Sorry, I haven't been home yet. I will post it soon. Promise!

 

Alright, finally got what that drawing. Reading your post further I am not sure that it is the same issue. The linkage that rotates to lift/lower the light hits a cylindrical stop that is made out of hard and brittle plastic and that broke off on my car. Unfortunately it is a large part that goes around the whole front of the car so I made this metal bracket to replace it:



The headlight motor attaches to a metal wall with 3 bolts. This mounts with those same 3 bolts but on the other side of the metal wall (side that faces the headlight). This replaced the broken TOP stopper. Worked like a charm.