How to Silence Noisy 2020 Corvette Pop-Up Headlights

How to Fix Pop-Up Headlight Noise on Your 2020 Chevrolet Corvette

The 2020 Chevrolet Corvette, while celebrated for its modern design and performance, can sometimes experience issues with its pop-up headlights. A common complaint is unusual noise emanating from the headlight mechanism. As one owner struggling with a different issue shared, "I will cut the wire on connector and ECM side and run up my own wire which I can then test to ensure it has fixed the issue before figuring out how to install it cleanly." (source). This guide will help you diagnose and fix the noise problems with your pop-up headlights.

Symptoms

The primary symptom reported by owners regarding the pop-up headlights is noise during operation. This noise can manifest in several ways. It might be a grinding sound as the headlights attempt to open or close. The noise could also be a clicking or whirring sound, indicating a problem with the motor or gears within the headlight assembly.

Another symptom related to the noise is intermittent operation. You may find that the headlights sometimes open and close smoothly, while at other times, the noise is present, and the headlights struggle to move. In some cases, one headlight might operate correctly while the other makes noise or fails to open or close fully.

In more severe instances, the noise can be accompanied by a complete failure of the headlight to operate. The headlight might remain stuck in either the open or closed position. This complete failure is often preceded by a period of increasingly loud or frequent noises. This failure can lead to safety concerns, particularly when driving at night.

The noise can also vary in intensity depending on the temperature. Cold weather might exacerbate the issue, causing the noise to be louder or more frequent. Conversely, warmer weather might temporarily alleviate the problem, although it's unlikely to resolve it completely. Pay close attention to the conditions in which the noise is most noticeable.

Most Likely Cause

The most likely cause of the noise in your 2020 Chevrolet Corvette's pop-up headlights is a worn or damaged plastic gear within the headlight motor assembly. Over time, the plastic gear can degrade due to age, use, and environmental factors. This degradation can lead to stripped teeth on the gear, causing it to slip or grind against the mating gear. The result is the noise you hear, and eventually, the headlight motor may fail completely.

The headlight motor assembly is responsible for raising and lowering the headlights. This assembly consists of an electric motor, a series of gears, and a linkage system. The plastic gear is a critical component in this assembly, as it transfers the motor's rotational force to the linkage that moves the headlight. When this gear fails, the entire system is compromised.

The location of the headlight motor assembly also contributes to the problem. It is typically located within the front of the vehicle, near the wheel well. This location exposes the assembly to moisture, dirt, and debris, which can accelerate the wear and tear on the plastic gear. The constant exposure to these elements can cause the plastic to become brittle and more prone to cracking or breaking.

Another contributing factor can be the age of the vehicle. Even if the headlights are not used frequently, the plastic gear can still degrade over time. The plastic can dry out and become brittle, making it more susceptible to damage. Regular use can also accelerate the wear, but simply the passage of time can be enough to cause the gear to fail.

How to Diagnose

To properly diagnose the pop-up headlight noise on your 2020 Chevrolet Corvette, follow these steps:

1. Listen Carefully: Pay close attention to the type of noise. Is it a grinding, clicking, or whirring sound? Note when the noise occurs, such as only during opening, only during closing, or both.

2. Observe Headlight Movement: Watch the headlights as they open and close. Do they move smoothly, or do they hesitate or stutter? Is one headlight moving slower than the other?

3. Inspect the Headlight Assembly: Locate the headlight motor assembly. This is usually behind the headlight housing, accessible from the engine bay or wheel well.

4. Check for Visual Damage: Look for any visible signs of damage to the headlight assembly. This includes cracks, broken pieces, or loose connections.

5. Test the Motor: Use a multimeter to test the headlight motor. Disconnect the motor and apply power directly to it. If the motor doesn't run or makes unusual noises, it may be faulty.

6. Examine the Gears: If possible, carefully disassemble the headlight assembly to inspect the gears. Look for stripped teeth, cracks, or excessive wear on the plastic gear.

7. Use a Scan Tool (Optional): While not always applicable to this specific issue, a scan tool can help identify any related electrical faults. Check for any error codes related to the headlight system.

8. Tools Required:

   • Screwdrivers (various sizes)
   • Socket set
   • Multimeter
   • Pliers
   • Work gloves
   • Safety glasses

Step-by-Step Fix

Here's a step-by-step guide to fixing the pop-up headlight noise on your 2020 Chevrolet Corvette. This assumes the issue is a worn plastic gear, which is the most common cause.

1. Gather Your Tools and Parts: Before you start, make sure you have all the necessary tools and a replacement plastic gear.

2. Disconnect the Battery: Disconnect the negative terminal of your battery to prevent any electrical accidents.

3. Access the Headlight Assembly: Depending on the design of your Corvette, you might need to remove the headlight housing or access the motor from the wheel well. Refer to your service manual for specific instructions.

4. Remove the Headlight Motor Assembly: Carefully disconnect the electrical connector to the headlight motor. Remove any screws or bolts holding the motor assembly in place.

5. Disassemble the Motor Assembly: Take the motor assembly to a clean workbench. Carefully disassemble the housing to expose the gears. Take photos as you disassemble to help you remember the order of the parts.

6. Inspect the Gears: Examine the plastic gear for any signs of wear, such as stripped teeth or cracks. If the gear is damaged, proceed to the next step.

7. Replace the Plastic Gear: Remove the old plastic gear and install the new one. Make sure the gear is properly seated and aligned with the other gears.

8. Reassemble the Motor Assembly: Carefully reassemble the motor assembly, making sure all parts are in their correct positions. Use the photos you took earlier as a reference.

9. Reinstall the Motor Assembly: Reinstall the motor assembly back into the headlight housing. Secure it with the screws or bolts you removed earlier. Reconnect the electrical connector.

10. Test the Headlight: Reconnect the battery and test the headlight. It should now open and close smoothly without any noise.

As one owner shared when tackling a similar electrical issue, "I will cut the wire on connector and ECM side and run up my own wire which I can then test to ensure it has fixed the issue before figuring out how to install it cleanly." (source). While this quote refers to a different repair, the principle of testing your work before fully committing to the installation is a valuable lesson.

Parts and Tools Needed

• Replacement plastic gear for pop-up headlight motor
• Screwdrivers (Phillips and flathead)
• Socket set
• Pliers
• Multimeter (optional, for testing the motor)
• Work gloves
• Safety glasses
• Service manual for your 2020 Chevrolet Corvette (recommended)

Real Owner Costs

Based on owner reports, the cost of addressing pop-up headlight noise can vary.

• DIY Repair: The cost of a replacement plastic gear can range from $10 to $30. Add to this the cost of any tools you might need to purchase.
• Professional Repair: If you choose to have a mechanic perform the repair, you can expect to pay between $150 and $300, including parts and labor.

For example, one owner reported spending $60 on fuel after getting a blower idler pulley bracket replaced ($60) (source), while another lost $200 on a track day due to an incorrect part shipment ($200) (source). These examples highlight the range of costs owners may encounter when dealing with automotive repairs. The cost of repair will vary based on if you chose to DIY or let a mechanic handle it.

Prevention

To prevent pop-up headlight noise and prolong the life of your headlight motors on your truck, consider these preventative measures:

• Regular Lubrication: Apply a small amount of silicone-based lubricant to the moving parts of the headlight mechanism. This will help reduce friction and prevent the gears from wearing out prematurely.
• Avoid Excessive Use: Limit the number of times you open and close the headlights unnecessarily. Each operation puts wear and tear on the motor and gears.
• Protect from the Elements: If possible, park your vehicle in a garage or under a cover to protect it from extreme weather conditions. Exposure to moisture, heat, and cold can accelerate the degradation of the plastic gear.
• Inspect Regularly: Periodically inspect the headlight assemblies for any signs of damage or wear. Catching problems early can prevent them from escalating into more costly repairs.

What Owners Say

Real experiences from CHEVROLET owners:

Success Stories

"Quote: Originally Posted by gpop1 Thank you sir! I will cut the wire on connector and ECM side and run up my own wire which i can then test to ensure it has fixed the issue before figuring out how to install it cleanly." — torquetube (source)

"OK, for the last few days I have been trying to get the glass into the doors and struggling all the way. I posted before that the passenger side vent window dropped right in and worked with no issues." — mccarley (source)

"I will cut the wire on connector and ECM side and run up my own wire which i can then test to ensure it has fixed the issue before figuring out how to install it cleanly." — torquetube (source)

Owner Experiences

"Thought we were in the clear until I was 5 miles from home on the return trip and BAM dreaded Reduced Engine Power dings on the DIC. Stuck on the side of the road until forcing it to clear and run properly again." — smitty2919 (source)

"I am probably going to have to change the studs in my car for the opposite problem when my Forgestar wheels show up. I am hoping to not have to tear the whole car apart to do it." — 03 Owner (source)

"Quote: Originally Posted by Mr. Black Made the next attempt to further see if the car is fixed of my P1516 random REP problem by driving the car to work today. 75ish miles of grueling bullshit traffic conditions." — smitty2919 (source)

Real Repair Costs

"I think that they are "Tool Shop" and they do the same thing and seem better made. The good thing is that they were much cheaper. $7.00 for a 24", $9.00 for a 36", and $10.00 for a 48"." — mccarley (source)

"The idiots send me two right kunckles instead of a pair, and the right one is the one that I don't need immediately. I'm going to lose $200ish on my track day scheduled for tomorrow." — Midwayman (source)

"Well I don't have anything that exciting to report, the car does live on once again. I put 60 dollars worth of 92 in it today after getting the blower idler pulley bracket replaced yesterday afternoon." — Mr. Black (source)

FAQ

Q: How long does it take to fix pop-up headlight noise?

A: If you are doing it yourself, replacing the plastic gear can take anywhere from 1 to 3 hours, depending on your mechanical skills and experience. Professional repairs typically take about the same amount of time.

Q: Can I drive with noisy pop-up headlights?

A: While you can technically drive with noisy pop-up headlights, it is not recommended. The noise indicates a problem that could lead to complete failure. Driving with a malfunctioning headlight can be dangerous, especially at night. It's best to address the issue as soon as possible.

Q: Is this a common issue on the 2020 Chevrolet Corvette?

A: While not every 2020 Chevrolet Corvette will experience this issue, it is a known problem, especially as the vehicles age. The plastic gear in the headlight motor assembly is a common failure point.

Q: DIY vs mechanic - what's recommended?

A: If you have experience working on cars and are comfortable disassembling and reassembling mechanical components, a DIY repair is a viable option. However, if you are not mechanically inclined or lack the necessary tools, it's best to have a professional mechanic perform the repair. Incorrect installation or assembly could lead to further damage or safety issues. As one owner suggested in a different context, "I will cut the wire on connector and ECM side and run up my own wire which I can then test to ensure it has fixed the issue before figuring out how to install it cleanly.” (source). This advice of testing and verifying could be helpful in this case as well.

Q: Where can I find the replacement headlight motor gear?

A: You can typically find the replacement plastic gear online at automotive parts retailers. Make sure to purchase a gear that is specifically designed for your 2020 Chevrolet Corvette's pop-up headlight motor.

Q: What type of grease should I use to lubricate the gears?

A: Use a silicone-based grease, which is resistant to water and temperature changes. Avoid using petroleum-based greases, as they can damage the plastic gears over time.