Headlight gear
Thread Starter
Melting Slicks
Joined: Nov 2003
Posts: 3,011
Likes: 9
From: Dublin GA
Headlight gear
Well I guess I've got to do the dreaded headlight gear replacement. My wife called me out to her car last night to "listen " to a new noise she had. The sec. I heard it I remembered the different post on here about the sound it made and sort of 
I have printed out the "gear replacement for dummies" sheet and look FORWARD to geting started on this. (I love modding, but hate repairs)
If anyone has any additional hints, please send post them.
I have printed out the "gear replacement for dummies" sheet and look FORWARD to geting started on this. (I love modding, but hate repairs)
If anyone has any additional hints, please send post them.
Burning Brakes
Joined: Oct 2004
Posts: 925
Likes: 4
From: EXTON PA
Use only the solid brass metal gear replacement on the repair. Some will still use the plastic design and some use a brass gear that reuses a design with a center that has a rubber core.
A easy repair
A easy repair
Melting Slicks
Joined: Aug 2003
Posts: 2,786
Likes: 7
From: Iowa
I agree, use the Brent Franker gear set, and replace both at the same time and not just the one that is failing, the other one will surely fail as soon as you get the first light put back together. just follow the instructions and you should be fine. I'm not sure which instruction set you have, but don't do what I did and actually remove the entire headlight assembly from the car. if you do you will never get it back into the right place and you will have to spend alot of quality time getting the headlight door covers to line up with the body once you are done.
go the method of removing just the headlight door itself. remove the cover, remove the two hinge bolts, remove the 10mm nut which attaches the headlight door arm to the motor, disconnect the headlight bulbs and you can remove the headlight leaving the rest of the bracket in. you should be able to unbolt and remove the headlight gear easily at this point
go the method of removing just the headlight door itself. remove the cover, remove the two hinge bolts, remove the 10mm nut which attaches the headlight door arm to the motor, disconnect the headlight bulbs and you can remove the headlight leaving the rest of the bracket in. you should be able to unbolt and remove the headlight gear easily at this point
Thread Starter
Melting Slicks
Joined: Nov 2003
Posts: 3,011
Likes: 9
From: Dublin GA
I agree, use the Brent Franker gear set, and replace both at the same time and not just the one that is failing, the other one will surely fail as soon as you get the first light put back together. just follow the instructions and you should be fine. I'm not sure which instruction set you have, but don't do what I did and actually remove the entire headlight assembly from the car. if you do you will never get it back into the right place and you will have to spend alot of quality time getting the headlight door covers to line up with the body once you are done.
go the method of removing just the headlight door itself. remove the cover, remove the two hinge bolts, remove the 10mm nut which attaches the headlight door arm to the motor, disconnect the headlight bulbs and you can remove the headlight leaving the rest of the bracket in. you should be able to unbolt and remove the headlight gear easily at this point
go the method of removing just the headlight door itself. remove the cover, remove the two hinge bolts, remove the 10mm nut which attaches the headlight door arm to the motor, disconnect the headlight bulbs and you can remove the headlight leaving the rest of the bracket in. you should be able to unbolt and remove the headlight gear easily at this point
the write up I have shows you how to remove the entire assembly. It is the write up titled "another how to for dummies, headlight gear replacement" Do you have a little more detailed write up (with photos
) or the method you have used. It certainly sounds more feasible. Thanks
Burning Brakes
Joined: Nov 2004
Posts: 834
Likes: 1
From: Keller Texas
Well its my turn now....mine has just started making this really bad sound and I know its the beginning on a failed gear...where do I get the replacement gear that everyone is talking about?
Former Vendor
Joined: Nov 2005
Posts: 8,995
Likes: 2
From: Spring Texas
St. Jude Donor '08
I just did one yesterday;
Tools needed:
torx 15
torx 20
Phillips head
8mm open end wrench
13mm socket
10mm socket
Flathead screwdriver (to help wedge out the raising arm from the gear axis)
7mm socket
20 minutes of fun.
Tools needed:
torx 15
torx 20
Phillips head
8mm open end wrench
13mm socket
10mm socket
Flathead screwdriver (to help wedge out the raising arm from the gear axis)
7mm socket
20 minutes of fun.
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Advanced
Joined: Oct 2005
Posts: 63
Likes: 8
From: Denham Springs LA
I also just completed the repair on my '01 and here is a hint: Make sure you securely tighten the motor to the gear assembly. There are four metal tabs that hold the motor to this assembly, use a small hammer and punch and tighten these tabs securely. Mine were loose, and every time the lights open and close, there is a lot of torque applied to this assembly, which caused the motor to pull away from the gear and thus strip it out. Brass is the way to go, but still make this adjustment. Jeff
