Ok headlight gurus here's one for ya.

Don't you love a good puzzle... On 96 there are nylon bushings where the headlight assembly rotates in the frame. If they are worn, I wonder if it's binding when gravity is moving things. What if you disconnect the linkage and rotate it to see if it's smooth? Wiring harness shouldn't be a problem because it is pinched to secure it as it comes through the same pivot.

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I wonder if you could have a problem with end play on the motor shaft.  If the motor shaft moves in and out it could cause the worm (drive gear) to bind against the driven gear.   The worm has slightly concave shape to the gear.  Haven't seen it in a Corvette headlight motor but I have see it in other worm gear drives.

Good luck and let us know what you find.

Bob
Woodstock, GA


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Bob - '94 Polo Green Coupe

Had a similar problem (gears replaced, wiring harness OK, connector good, not binding or hitting anything, etc.) 

same thing happened to me, but it was the hoods (engine) lights wiring that sagged when I closed the hood, what it did to the motor was cook the winding's and the brush holders so bad i thought it was toast, but I varnished the winding's and straitened out the brush holders as good as I could and it worked for over a year. it's starting to act up again and was wondering if anybody has a motor RH 95 c4 conv.. thnx jay

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found the bucket grommets for my 2002 headlights on ebay