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1985 Corvette Headlight Motor Brush Replacement

V-6 Camaros rule!
Posts: 26
Joined: 08/09
Posted: 09/22/12 11:58 AM

Headlight motors on the 1985 Corvettes use a funky brush assembly. Replacing the gears is a no brainer but when the electrical comutator brushes wear down to nothing you are faced with a high priced cure, replace the motor with another used one, factory new if you can find one, or after market Chinese stuff. (There are several places to buy overhauled units but I am not sure if they actually replace the brushes as part of the overhaul).  Unless you try this repair that I did. I already did the gears, all the motor needed was new (non existent) brushes. I obtained a random brush from our alternator overhaul shop, a high copper content one that would hold solder. Used a dremel tool with a slim cut off wheel to fabricate 2 very tiny brushes. Carefully shaped them to the correct dimensions, solder tinned the back side of each one, heated and removed the old brush stubs, then soldered in my new hand made brushes. Motor has another 25 years of life left in it now, works great and the price of materials was zero. I shot a few photos while I was doing all this, you may have to zoom in on them to really see up close details.  

IMG 6149 Zps14538c04

IMG 6153 Zpscbb43436[/img]

IMG 6151 Zps83ec0f1b[/img]

IMG 6157 Zps5cd8c37b[/img]

IMG 6159 Zps203231a5[/img]

IMG 6159 B Zps6b2924e3[/img]  

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My first time was in a Chevy
Posts: 181
Joined: 04/12
Posted: 09/24/12 04:41 PM

thanks John...

that should help a LOT of readers...

you might also want to cross post that again over at VETTEWEB as that is the active magazine in print..

corvette fever was merged into vetteweb early 2012...  

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V-6 Camaros rule!
Posts: 83
Joined: 01/12
Posted: 09/25/12 11:44 PM

Thanks there are a lot of Vette guys out there that have that same problem. Great Post...


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