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Problem: Psgr side headlight would rotate part way, then hang free while the motor spun and eventually shut off.
What I did: I replaced the Delrin bushings, which were NOT worn bad at all. (the driver's side was just the normal "bum bushings" symptoms and that fixed up no problem). I did have some trouble getting the right side gear removed and replaced but eventually everything lined up.
BUT - passenger side symptom is still the same. It starts to open, then flops loose. You can take your hand and flip it up and down. The gear teeth look fine, not chewed up at all.
Looking at the shaft, it has splines on it. But the inside of the metal cover on the gear does NOT have splines (if it used to, they are worn off). Seems to me this could be the problem. Anybody else had this issue? Any suggestions on a source for that, if it is indeed the problem?
Headlight motor gear splines
