Headlight gear issue again?
Thread Starter
Burning Brakes
Joined: Oct 2001
Posts: 860
Likes: 40
From: Woodforest
Headlight gear issue again?
A couple of years ago, had the famous gearissue with the headlights on my 2004. Did the brass gear replacement, all good. Now the issue raises it's ugly head again. Anyone have to do this twice? How did you take apart the gear case since the original repair included epoxy on the case cover. Am I resigned to buying new gear sets?
Team Owner
Joined: Jul 2012
Posts: 34,479
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From: Central PA. - - My AR15 identifies as a muzzleloader
I believe in the Beer Fairy
Mines a 98, so it may be different, but I didn't have to use the epoxy. It was included, I just don't recall what for.
If you used it for sealing things up, remember that a heat gun will loosen it some. But since they are all plastic housings, you might melt them and of course that's no good. Be really careful not to over heat. Maybe an oven is better, say at 150-175 or so. Not enough to make plastic parts fail, but enough to weaken that epoxy.
It'd be interesting to hear what you find was the failure this time. That bronze gear isn't supposed to. Maybe now the worm gear is stripping.
If you used it for sealing things up, remember that a heat gun will loosen it some. But since they are all plastic housings, you might melt them and of course that's no good. Be really careful not to over heat. Maybe an oven is better, say at 150-175 or so. Not enough to make plastic parts fail, but enough to weaken that epoxy.
It'd be interesting to hear what you find was the failure this time. That bronze gear isn't supposed to. Maybe now the worm gear is stripping.
Heel & Toe
Joined: May 2012
Posts: 20
Likes: 1
From: Huntsville Alabama
Have you checked the headlight control module located under the passenger side headlight? The seam can seperate over time and allow water to get in shorting out one of the voltage regulator circuits. A new one is a couple hundred dollars. I bought a used one off Ebay and before installing it put a bead of RTV around the seam so water doesn't get in.
Thread Starter
Burning Brakes
Joined: Oct 2001
Posts: 860
Likes: 40
From: Woodforest
I haven't checked the Headlight control module, but electrically, it seems fine. The power at the drivers side headlight connector matches with power to the passenger side which is working properly.
What happens is the drivers side won't come up, but the passenger side will. Also, doesn't happen every time I use the lights. Seems if I've opened it manually, it will work for the next two or three attempts. I can open the drivers side with the manual system, but have to "help" it up by lifting a little which to me, indicates stripped gears.
I'm kinda waiting for the temps to drop down a little here in Houston, working in that evening heat is a little tough right now. When I get the time and inclination, I'll try to remove and break open the case and see if the brass has stripped, or if the worm gear on the motor might be bad.
What happens is the drivers side won't come up, but the passenger side will. Also, doesn't happen every time I use the lights. Seems if I've opened it manually, it will work for the next two or three attempts. I can open the drivers side with the manual system, but have to "help" it up by lifting a little which to me, indicates stripped gears.
I'm kinda waiting for the temps to drop down a little here in Houston, working in that evening heat is a little tough right now. When I get the time and inclination, I'll try to remove and break open the case and see if the brass has stripped, or if the worm gear on the motor might be bad.
Advanced
Joined: Jun 2010
Posts: 77
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From: Virginia Beach Virginia
Does the headlight come on, but not pop up? I had a similar issue, turns out the headlight motor would tighen down too hard and couldnt open itself. The suggestion from the guy I bought my replacement gear from was to cut a piece of 1/2 inch hose wide enough to fit over the mechanical stop it hits while closing and that will fix it. Worked on mine, havent had a problem since.
