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OK, so I replaced the nylon gears in both headlight motors and they worked great for about a month. It was then that I found the epoxy didn't hold the case together. I re-epoxied them and they held for another month, or so before separating. I now have the cases held together with nylon tie straps. I've thought of using JBWeld, but have not done that yet, as I suppose I'll not have any better luck. It seems the case halves are too smooth for bonding agents to hold adequately. I'm now thinking of cutting a couple straps from aluminum, bending them around the two cases, then epoxying them. This won't look pretty.
Has anyone else experienced this very frustrating situation? If so, please let me know how you conquered it.
You must have an early 2000's, my case had 3 bolts with a gasket. I just ordered brass gears for mine. I think the 2000 and up had plastic cases, next time I'm just going to do the headlight conversion.
I did see the brace on one of the kits I looked at for the 2000's and up. Mine will be back together Monday when my gear comes in. Good luck with yours.