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Are you using headlights with glass? The plastic is what one should use in our popups since they weigh less. MidAmerica sells them. I now have 125k+ miles on original motors/gears with no problems. Check it out.
I THINK Im running factory headlights.... I just found out upon inspection, that its not the gears that failed, its the little rod that connects the motor assembly/arm to the headlight . It fell out. I found a washer and the little rod... just need to figure out how to put it back on... didnt see the part (s) in Ecklers catalog..