Head light motor gear replacement
Le Mans Master
Joined: Sep 2013
Posts: 8,900
Likes: 1,074
From: Wisconsin
You can get a rebuilt motor assembly for $102 at Amazon.com, I think new ones are over twice that. There are also rebuild services that will repair your unit if you don't want to mess with it yourself.
Melting Slicks
Joined: Jan 2009
Posts: 3,275
Likes: 739
From: Miami FL
You received good advice in the previous posts. Let me just add some links so you have more info on hand.There are several kits available to replace these plastic gears, but this one is one of the best (pay attention because there are 2 different kits: one for "97 to early 2000" and another for "late 2000 to 2004"). Read these step-by-step directions to understand what's involved. If you have to replace the gears and you decide to go the DIY route, you could save money and they will last forever
You might need these as well (the rubber bump stops).
There is a TSB, that calls for shimming the driver's side motor. The parts needed for this are included in the above mentioned kit.
Racer
Joined: Nov 2014
Posts: 387
Likes: 47
From: Redmond, WA Bermuda Dunes, CA Chelan, WA
Head light gear replacement is easy. I did both of mine 8 months ago. first one took 1.5 hours as I was learning. 2nd one - 45 minutes. yes my 2000 had the gear case halves glued. Patience to separate them and yes super glue to put them back together. Careful with the glue as you don't want to get it anywhere but on the case halves. Also let it sit for 10 minutes (or one home brew beer) before reassembly.
Melting Slicks
Joined: Jan 2007
Posts: 3,021
Likes: 133
From: Conejo Valley CA
Melting Slicks
Joined: Mar 2012
Posts: 2,800
Likes: 456
From: USA
I did both of mine and found someone had replaced the passenger side with a brass gear already. PO had used some kind of clear epoxy on it and the cover had come completely off. Good thing I caught it when I did. Good luck with your repair
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Le Mans Master
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From: Wisconsin
http://www.cardone.com/Products/Prod...829130H&p=rock
92 bucks with lifetime warranty at Rock Auto
92 bucks with lifetime warranty at Rock Auto
Last edited by JR-01; Jan 16, 2016 at 07:04 PM.
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I would go with the brass replacement gears, but if you're not comfortable with doing that, just get the complete motor and replace it as a unit.