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@%#$ Headlight issue.

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Old Dec 20, 2024 | 12:53 PM
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Default @%#$ Headlight issue.

2004 Headlight motor issue.....

I have replaced the driver side headlight motor three times now. First the factory motor, then a motor from Mid America and now a motor from Amazon. The passenger side has never failed.
Stops are in great shape and everything is smooth, looks and works good until it starts grinding. Last motor only lasted about 20 cycles. Fourth motor about to go in.

Is there anything else I should look for?

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Old Dec 20, 2024 | 01:07 PM
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Originally Posted by CCRed
2004 Headlight motor issue.....

I have replaced the driver side headlight motor three times now. First the factory motor, then a motor from Mid America and now a motor from Amazon. The passenger side has never failed.
Stops are in great shape and everything is smooth, looks and works good until it starts grinding. Last motor only lasted about 20 cycles. Fourth motor about to go in.

Is there anything else I should look for?
I replaced my right side motor after the gears wore out. After that, it would randomly not open. Eventually I took off the top again and lubed all the arms/linkage joints with WD-40 and it's been working flawless since then. just a thought.
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Old Dec 20, 2024 | 01:27 PM
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Originally Posted by CCRed
2004 Headlight motor issue.....

I have replaced the driver side headlight motor three times now. First the factory motor, then a motor from Mid America and now a motor from Amazon. The passenger side has never failed.
Stops are in great shape and everything is smooth, looks and works good until it starts grinding. Last motor only lasted about 20 cycles. Fourth motor about to go in.

Is there anything else I should look for?
Have you ever considered rebuilding the factory motor with bronze gears?
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Old Dec 20, 2024 | 02:55 PM
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Appreciate the replies!
I did lube it up each time. It moves very smoothly. There is nothing dragging. Stock headlamp bulb.
As far as the brass gears.... I have seen a few posts over the years saying if you replace the plastic gear with brass then something else more expensive breaks.

Let me ask this...
What causes the headlight motor to stop running once it hits the stops? I tore the last one apart but did not see any limit switches.
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Old Dec 20, 2024 | 04:36 PM
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I did the brass gears over 10 years ago and they haven't missed a beat. The kit I used included a steel backing plate to prevent plastic housing from flexing under load.

No limit switches. It senses over-current when it hits the hard stop.
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Old Dec 20, 2024 | 04:46 PM
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Originally Posted by CCRed
Appreciate the replies!
I did lube it up each time. It moves very smoothly. There is nothing dragging. Stock headlamp bulb.
As far as the brass gears.... I have seen a few posts over the years saying if you replace the plastic gear with brass then something else more expensive breaks.

Let me ask this...
What causes the headlight motor to stop running once it hits the stops? I tore the last one apart but did not see any limit switches.
The amperage spike of the motor stalling tells the quad driver to stop supplying power to the headlight motor. Similar in function to the solid state circuit breaker in the power window. Once the amperage spikes, the breaker opens to stop power to the motor. Resets when you release the button
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Old Dec 20, 2024 | 06:22 PM
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OK thank you all. Thats what I thought and I should be able to test that.

Appreciate the replies!
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Old Dec 20, 2024 | 07:21 PM
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Originally Posted by CCRed
Appreciate the replies!
I did lube it up each time. It moves very smoothly. There is nothing dragging. Stock headlamp bulb.
As far as the brass gears.... I have seen a few posts over the years saying if you replace the plastic gear with brass then something else more expensive breaks.

Let me ask this...
What causes the headlight motor to stop running once it hits the stops? I tore the last one apart but did not see any limit switches.
I don't buy that. Many here have used the brass/bronze gears with no issues. That would be my next move. The motors use resistance to sense when they need to stop. The most common failure I've seen here on the forum is the plastic gears get old and brittle, then eventually split in 2 pieces. Good luck.....
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