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I discovered last spring that I had a torn actuator boot on one of my headlights. I saw the tech article from Zip on how to replace it. Everything worked out good and it was back up and working. A week ago I discovered the same light was working slow on coming up. I noticed that my dust boot was sucked in all around the shaft and on further investication I discovered the new boot was torn up again. I replaced it but I am wondering if I am doing something wrong or does that just happen from time to time. Anyone know for sure?
I have had good luck with repop seals by coating them with silicone grease. It will help them last longer by conditioning the rubber and also it allows them to move freely and not bind up and tear.
There was an online article with a picture that showed you how to put the little boot on backwards! Hope that wasn't your problem. The little cone shaped rubber thing. I have also heard (never tried it) that you can use baby bottle nipples as a cheap substitute if you get tired of paying $10 per for the repops.
Thanks guys for you imput. The picture does show it going on backwards, however I did put mine on the right way! I will try the greese. It makes since! Thanks everyone, Mark.