I am working on a 1993 RH headlight assembly. The knurling failed and the shaft just spins inside the pot metal part. I am going to pin it and Loctite it but would like to know the dimension of how far the short side sticks out so I can get it right.

In case this doesn’t work does anyone have an extra one of these laying around?

 

If I remember correctly you need a 5/16 punch to press out the index pin, and when installing it, should not any part of the pin sticking out of either side of the shaft.

Imagine others will chime.

 

The parts were not pinned from the factory. The pot metal part is where the "pellets" ride inside the plastic gear. the shaft sticks out on the short side into the housing. The longer side extends through the cover and is where the pivot for the headlight assembly mounts.

 

With out pulling apart another unit to get a measurement the only thing I could suggest is putting the striped parts where they belong without the gears and pucks to get the depth you're looking for.
Really interested in how it turns out for you, had the same problem 3 weeks ago the Right one in the car did this, installed my spare motor it to did same thing. gave thought of doing the roll pin thing but the idea of trying to drill Stainless with Harbour Frieght drills and no drill press. Then I found out you can get a rebuilt one from Napa for $90. Picked it up. Other than a little wiring details that needed to be corrected, when installing the new motor you need to take a few wires from headlight connector and they put wrong ends on the wires so I used the ones in the car, removing their open end wires after that it went in perfectly

 

I contacted Rodney Dickman and he had a Fiero part handy which he measured. He said it extended 7.2 mm so that's about where we put it. drilled and pinned and also used green Loctite on it. I have been working late for a few days but hope to put it back together Wednesday evening and give it a "spin".

UPDATE: the Green loctite and roll pin seem to have worked for now. The headlight moves as it should with no excessive motor running.