Prior to one of the magnets in the right hand headlight door motor breaking free, I had no headlight door issues. I have repaired the loose magnet. The motor on the bench power supply runs very nicely in both directions and very quiet. I reassembled the entire headlight assembly and installed on my 1987.

When the headlights are turned on, the left door opens instantly, the right hand door has a 3 to 5 second delay in opening. It closes instantly as does the left door.

While the motor was open, I cleaned the (2) switch contacts. On close up, I made sure the plastic tab that operates the (2) switches was centered and inside the plastic moulded area for it. I understand how the worm gear gets a pre load and pulls/pushes the motor shaft to make the switches work when the door is fully open or closed.

I metered the motor feed line at the connecter and find when the headlights are turned on, I get instant power. The same is true when the headlights are turned off power at the connecter, power is removed. At the end of work today, I noticed the motor was clicking every few seconds with the headlights in the down position. Inside the motor I did see what appears to be a thermal overload switch. The Electrical Supplement FSM does not show this switch anywhere on the headlight motors. No where in the FSM or the Electrical FSM Supplement can I find any mention of where to set the motor's range after its been opened and repaired.

This is what I believe is happening, but dont know how to set up the motor. In the down position, the internal motor switch is not being pushed open. Since the switch is still closed with power applied, the thermal overload switch is opening and closing due to the stalled motor in the down position. When I command the headlights to come up, the delay is due to the thermal delay being open. The 3 to 5 second delay corresponds to the clicking I hear from the motor. When the thermal overload switch opens, then the headlight goes up.

So my question, After you have had the motor all apart for cleaning/repair, where do you set (Clock) the large drive gear when inserting in the case. There is no way to index the motor shaft/armature/worm gear as its movement is controlled by a load at the extreme headlight movement at the end of the travel.

Sorry for the long post, but I wanted to explain all I have done and found. As I mentioned, unless I keep overlooking it, I find no mention of a total motor re-assembly any where in the FSM or the Electrical FSM Supplement.

Thanks for any tips.

8Valve

 

an easier way to'clock' those would be to turn the manual *** on the outside of the motor till both are all the way closed and snug, that should get them back in time with each other, if not then small adjustments with that *** should help. I had the same issue with my 87, never found any internal clock method either, hope this helps

 

Thanks for your post.
Presently when the Headlight door is at each end of travel (Up/down) the **** is snug and tight. The answer may be as simple as I bend one of the limit switch contacts slightly when cleaning?

8Valve

 

thats possible, I was lucky not to have to get that far into it , do a search on here , I got alot of good info from one of the other members.