Headlight motor rebuild

[bamawrx]

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Just completed a power headlight motor rebuild on my 90. Purchased the kit from Mid America, and they only showed a bronze gear for the ‘90. I was concerned because mine had a plastic gear in it, but I figured I’d go for it. After taking the assembly off the car and disassembling the gear housing with the help of the guide from this forum it was time to remove the old destroyed plastic gear. The housing was full of ground up plastic and delrin.

It was a bear to get out the old plastic gear as mine was stuck due to ground up plastic bits. I finally got it all out and cleaned up. Next was to install the new bronze gear with the three new delrin bushings onto the old shaft. It was so tight a fit that I had to press the parts together with my bench vise.

I thought I was going to break something it was so tight, but it went together into a solid unit that dropped right back into the motor housing. I greased her up and reassembled the housing and reinstalled the headlight assembly. She tested out great with rapid up/down with no continued running after reaching full up/down positions.

It was during this test that the drivers side started acting up, and now continues to run after reaching full up/down. Guess its time to order another rebuilt kit! Now it know better how to do the work, so it should be much easier next time. The “how to” on this forum was invaluable. I don’t think I would have attempted the task without it.