JD1964

What exactly is the repeating clunking noise when I turn off the headlights?

94flavette

Delrin bushings inside the motor are gone. The motor is not getting proper resistance once the light opens/closes to shut off so it runs for a bit of time. Very popular topic on here.

5 out of 10 on difficulty to fix. Be patient.

Richard Raichert

Replace the plastic gears and bushings (both sides) with brass gears and new bushings that are available at Ecklers or others for about $60 each side. Mine made the same noises so I changed even though I rarely use the lights!

JD1964

To expand on the issue;

I have yet to fix the headlight clunking issue but while doing other diagnostic tests I had the battery negative cable disconnected. When I hooked it back up, the headlight motor did the clunking thing. I can duplicate it every time I disconnect and reconnect the battery cable.

I know the headlight motor needs repair and such, but can you explain why it cycles when the battery is hooked back up? Maybe its normal but if so, I just want to understand why it does this.

MyOtherCar

same thing occurs when you shut off the engine.

tlong

The bushings are available at Autozone or Advance. They are Dorman Help window gear plugs. Perfect fit and far cheaper.. Bronze gears are a waste of money. It's always the bushings turning to powder.

JD1964

I didnt realize I could get them off the shelf at Autozone or I would have done that. Instead I ordered from ebay.

MyOtherCar

tru dat

auggy

tlong is dead right. Forget the metal gears--you don't need them. Bushings $8 at Advance if they have them.