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I'm in the middle of replacing headlight brushing and was having a time of pulling the gear out of the housing. After backing off the worm gear adjustmnet screw, I turned over the housing and gave it a nice tap with my hand and a small steel ball bearing fell out. It appears to be out of the hole where the adjuster screw and worm gear almost meet and looks as though it just rides between the first thread of the worm drive. Any thoughts on where this ball bearing came from and where it should be installed.
It goes on the top of the shaft between it and the adjusting screw. You should see a little dimple on the end of the shaft.
Just a tip on placing this ball bearing at the end of the worm gear. I used a magnet (pick-up tool) and placed it on the worm gear inside the housing and then moved the bearing around with a tooth pick until centered on the tip of the worm gear. Then closed the adjustment screw to the original spec.
I replaced my headlight bushings a few weeks ago and they work fine. I didn't have the ball bearing come out as you indicated, but from my research and with the help of tons of people here on the forum I noticed one article suggested putting a dab of white lith grease on the dimple to help hold the ball in place as you reassemble it. Maybe this will help you too.
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