Found a great replacement for the headlight gear inserts!

[aod]

At the local auto parts store (Advance Auto, but I'm sure any auto store carries these), I found in the section where the miscellaneous interior bits are like door lock knobs, window cranks, stuff like that. There is a box of window regulator gear plugs. They are a hard rubber so they should last. The box comes with three of them, so it is perfect. These particular ones are from HELP! and they said they were for 2003-1965 (yeah, the year range is backwards) Fords on the back of the box. I put them in mine and it fit together nice and snug.

[WB9MCW]

Got any pic's of the swap out?

Good info for sure.

[aod]

Got any pic's of the swap out?

Good info for sure.

I didn't even think to take pictures, sorry. I'll do that when the driver side one needs to be done, which I think will be soon. They are from HELP! and they are part #74410. They are .595" diameter and .429" high. Here is a picture of the box that I found online:

[VetteMed]

looks just like the pieces I bought on ebay for around $6 for both sides, IIRC.

[LGAFF]

Dorman product...also have check valve and the makeshift PCV top in the same section.

[aod]

looks just like the pieces I bought on ebay for around $6 for both sides, IIRC.

That's a lot cheaper than getting it at the auto parts store. They were around $8.50 for 3 of them. It wasn't a big deal though, I had the assembly apart and wanted something quick to fix it with. These worked out way better than my original idea which was to use nylon spacers in there.

[gbrtng]

Let us know how the hard rubber coexists with the delrin parts after a few years. As for me, I'll stick with the plastic parts MAD sells for $10.

[aod]

Let us know how the hard rubber coexists with the delrin parts after a few years. As for me, I'll stick with the plastic parts MAD sells for $10.

From what I can tell, Ford window regulators have been using this same setup for years with a delrin outer gear and everything. The hard rubber absorbs shock better, which makes more sense in a window regulator setup where many times the gear is subjected to moving one way then suddenly having to move the opposite way. I can't see having the additional shock absorption as a bad thing with the headlight motor gear though. Window regulator gears are subjected to much more abuse than our headlight gears are, I'd imagine.

I'll certainly post something up if anything wears or breaks prematurely though. If the gear happens to break, I have seen some models (or maybe even certain years) of Ford window regulators that have a metal gear in them. I'm willing to bet they are the same size and could be used in our headlight motors. If it happens I'll be doing more research to find out what model(s) and/or year(s) had the metal gear and find one in a junkyard to see if she fits. :)

[aod]

Was going through old posts to look for some old info and ran across this one. Nearly 12 years later and they are still working great!

[HAWAIIZR-1]

Was going through old posts to look for some old info and ran across this one. Nearly 12 years later and they are still working great!



Thanks for taking the time to provide a long-term update. 🤙🏼


Sent from my iPhone using ZR-1 Net Registry (http://r.tapatalk.com/byo?rid=90383)

[aod]

So, 13 years later (damn the luck) and the first one I did in 2009 completely disintegrated. It looks like ~13 years is about the lifespan of these. I'm thinking delrin might last a little longer.