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A very common problem with the C5 headlights is the long adjuster shaft is very easy to break. Also the Torx end on the shaft is fragile and can become stripped off the adjuster rod. I have not seen the short adjuster shaft breaking so for now I am only supplying the long one.
Sometimes called the golden rod as they are plated yellow.
I pondered a long time on how to make these. Having the gear made was not cheap or easy. One day I had an idea. Reuse your old gear.
A helpful tip: Before you remove the old long shaft/gear take a few measurements so when you are finished you can adjust it close to the original setting before reinstalling the assembly back into the headlight assembly.
Tip: As you take this assembly out of the headlight bucket and take the assembly apart - take some pictures so you can see how it goes back together. Do one side at a time if you are doing both sides. That way you can reference the other side to see how it goes back together.
With the long rod removed you will need to cut the gear off the shaft:
The next step is to sand the back of the gear to make it smooth.
Now you need to drill the old gear out with the drill bit included in the kit. Included in the kit is a Norseman 3/16"drill bit. The highest quality drill bit made in America. It will drill the hole to a very exact 3/16".
Important: This has to be done in a drill press. No exceptions! The hole has to be straight and precise. Do not try to do this with a hand drill!
You now use the aluminum piece to hold the shaft perfectly straight and hammer the shaft into the gear.
You now have a HD long adjuster shaft:
I had these made with a 1/4" hex on the end. It is not all that easy to machine a Torx into the end of the shaft.
Available as a single kit or double kit:
Tip: The biggest reason IMO the long shaft breaks is the shaft the gear rotates gets slightly corroded over time. This will be evident when you take it apart. You will probably find it very hard to rotate. The corrosion in the depressions is probably not a huge problem. But one can take some very fine sand paper and sand the threaded area on the tips to make it smooth again. When reassembling put silicone grease on all the moving parts. This will make it easier to rotate and keep it from corroding again in the future.
Also take the short one apart, clean it up and silicone grease it.
Shipping: Shipping in the USA via First Class Mail is $6.00
Shipping to areas outside of the USA: Generally I ship postal air first class mail. Shipping varies depending on what country they are going to. It ranges from $11.50 to Canada to $17 or more to Australia etc.
I do not offer free shipping.
Because I use postal flat rate boxes for heavy orders there is no program that can add the proper amount of shipping to every order. So all shipping is added manually by myself after you place your order. That is explained here: Shipping added later explanation
When you place an order the shipping amount will show $0.00. Soon after you place an order you will receive an email confirmation that shows the amount of shipping that was added to your order.