Headlamp motor re-install problem
Thread Starter
Pro
Joined: Jul 2004
Posts: 681
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From: Columbus Indiana
Headlamp motor re-install problem
I removed my RH headlamp motor & gearbox assembly and disassembled it, cleaned all of the old grease out of the gearbox and gears, re greased it and reassembled it.
I am currently trying to reinstall the assembly in the car. The assembly is about 1/8" from being fully seated, so (of course) I can't reinstall the retaining clip. I have wiggled it, pushed on it from the end with my hand, and even tried tapping lightly with a hammer, to no avail.
FWIW: when I removed it from the car I had to wiggle and pull quite a bit to get it off. Also, when I reassembled the gear box, I rotated the gear 180 degrees, so unworn teeth we in contact with the worm gear.
Am I missing something, or are there some tricks for getting this back fully seated?
Thanks, in advance, for any help.
I am currently trying to reinstall the assembly in the car. The assembly is about 1/8" from being fully seated, so (of course) I can't reinstall the retaining clip. I have wiggled it, pushed on it from the end with my hand, and even tried tapping lightly with a hammer, to no avail.
FWIW: when I removed it from the car I had to wiggle and pull quite a bit to get it off. Also, when I reassembled the gear box, I rotated the gear 180 degrees, so unworn teeth we in contact with the worm gear.
Am I missing something, or are there some tricks for getting this back fully seated?
Thanks, in advance, for any help.
Le Mans Master
Joined: Feb 2008
Posts: 5,215
Likes: 447
From: NJ Hockey beer league
Look at the shaft and try to get a bead on where it's at then move the headlight door slightly to align the shaft. Don't be surprised if the headlight is sitting in an odd position until you cycle the motor. You also might try dressing the rectangular inner portion of the gear with a small file to ease installation. 
Pilot Dan
Pilot Dan
Last edited by Pilot Dan; Feb 7, 2012 at 01:05 PM.
Thread Starter
Pro
Joined: Jul 2004
Posts: 681
Likes: 39
From: Columbus Indiana
Look at the shaft and try to get a bead on where it's at then move the headlight door slightly to align the shaft. Don't be surprised if the headlight is sitting in an odd position until you cycle the motor. You also might try dressing the rectangular inner portion of the gear with a small file to ease installation. Pilot Dan
Pilot DanEdit 1: Problem solved. There is a white split plastic bushing which "stayed" with the headlamp assembly when I pulled the motor/gearbox. This bushing wasn't piloting properly into the hole in the gearbox. When I pulled the assembly as you suggested to dress the inside of the gear, I saw the bushing. Pulled it off and installed it on the gearbox/motor assembly and it slid right on.
Working with the hood on, and using a mirror is not easy for me. Having a hard time learning to move in the correct direction. I probably should have removed the hood.
Thank you very much for your help.
Last edited by cam30era; Feb 7, 2012 at 01:47 PM.
Melting Slicks
Joined: Jul 2005
Posts: 2,554
Likes: 381
From: Strongsville, OH
2016 C2 of the Year Finalist
Looks to me as though the plastic shaft bushing is preventing the full seating. I think I can see it a bit cocked on the outermost part of the shaft which would prevent full seating. Make sure the plastic bushing is fully seated in the bracket attached to the motor. I had the same problem and found the bushing would move out of the hole when working the motor over the bucket shaft. 
Dave
Dave
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Joined: Jul 2004
Posts: 681
Likes: 39
From: Columbus Indiana
Looks to me as though the plastic shaft bushing is preventing the full seating. I think I can see it a bit cocked on the outermost part of the shaft which would prevent full seating. Make sure the plastic bushing is fully seated in the bracket attached to the motor. I had the same problem and found the bushing would move out of the hole when working the motor over the bucket shaft. Dave
DaveThanks, again guys. This forum is absolutely fantastic for help.
