OK, so I got the brass gears from Brent and split open each headlight motor, replaced the gears, greased 'em and epoxyed them back together on my 01 vert. Reassembled both headlights and they worked just fine. Now we are on vacation, left NY for Hilton Head. A few nights ago, unfortunately left the dome light on and had to get a jump start. Now, when I turn the headlights on and then off, the driver's side retracts, then pops back up again. When I remove the boot from the hand operate shaft area, I see it revolve twice as long as the passenger side, again causing it to retract them pop up again, while the passenger side works fine. The nuts are tight on the shafts. And why did this work before and not now? Is it possible that the dead battery has something to do with it? Is the computer somehow sensing that the light is in the wrong position, and that is why the motor shaft is spinning twice as long? I was SOOO proud of myself for fixing these headlights, and this really has me bummed out. Any suggestions would be greatly apprecited. By the way, what a great traveling car. My vert with a TomTomGO 910 was a great combination! Thanks DAN

 

is the epoxied cover still on? if the cover has let loose (happened to me) the gear will back out of the housing and won't work properly.

after my epoxy cover failure, i drilled small holes thru the cover and housing and twist tied 5 or 6 cotter pins to clamp the covers on.

works fine for me now.

 

I am hoping they are still in place. I used a good amount of epoxy, and I clamped then for 24 hrs, then reassembled them. I have seen another vendor on the forum that offers a cllamp that is anchored by the mounting bolts to keep the covers in place. Unfortunately, I had already got the gears from Brent F. AND I am on vacation, and I am not sure I have the right tools to get into this again. But it just pi$$es me off so much that they don't work now...so I guess my wife might make me wait till we get home to deal with the problem...