* Gear Meshing: The most probable cause is improper meshing of the replacement main gear with either the worm gear (the one the motor turns) or one of the plastic rotating parts. Even a slight misalignment can cause one headlight to go in the opposite direction. Carefully examine the gear teeth and ensure they engage correctly and smoothly. There's a specific orientation; if you have diagrams or photos from disassembly, consult them.
* Plastic Rotating Parts (Pulleys/Arms): These parts have specific positions and orientations. If one is even slightly off, it will reverse the direction of the headlight. Re-examine the orientation of these parts relative to the gear and the motor shaft. Look for any markings or alignment tabs on the parts themselves. A small misalignment here can have a significant effect on direction.
* Internal Casing: Although less likely if you didn't disassemble the motor casing significantly, ensure that the internal components haven't been reassembled in a way that restricts movement or causes binding. A slight bend or misalignment within the motor housing can affect the mechanical advantage and lead to opposite movement.
* Motor Rotation: While you mentioned wiring isn't reversed, double-check that the motor itself is rotating in the correct direction. If the motor is wired correctly but somehow rotates in reverse (a faulty motor or a previously unnoticed internal problem), it would cause this symptom.
Troubleshooting Steps:
1. Visual Inspection: Carefully examine both headlight motors, comparing them side-by-side. Look for any discrepancies in gear meshing, the position of the plastic parts, or any obvious misalignments.
2. Manual Rotation: With the motors disconnected from the power, try manually rotating the gears. They should rotate smoothly and without binding. If one feels stiffer or moves in a way that seems different from the other, that's the problem area.
3. Partial Reassembly: If you're still unsure, try a partial reassembly. Put the main gear and one plastic part back on. Test the motor's movement. Then add another part and test again. This process of elimination will help pinpoint the problematic component.
4. Reference Materials: Find a service manual or detailed disassembly/reassembly guide specific to your Corvette C4 headlight motor. These often include diagrams and exploded views that can be invaluable. Online forums dedicated to C4 Corvettes may also have helpful information.
If after these steps you still can't resolve the issue, it might be worth seeking the help of a qualified mechanic experienced with Corvette C4s. They'll have the tools and expertise to diagnose and fix the problem efficiently.
