Please note that it is wise to repair one headlight motor at a time. That way if you get confused you can look at the opposite side as a reference. Also note that the shaft exits different sides on opposite motors.
Please rear and fully understand these instructions before you begin.
The new headlight motor rebuild kit should include:
Brass Gear
Grease
Epoxy
Mixing stick
1. Raise the hood and disconnect the negative ground cable before starting any repairs. Locate the headlight motors beside each headlight assebly.
2. Raise the headlight. This will need to be done manually. Remove the rubber cap from the headlight motor. After you remove the cap you will see a knob. Turn this knob with your hand to raise the headlight. If the internal gears are stripped you may need to help raise the headlight with your hand as you turn the knob.
3. Unplug the headlight motor from the headlight electrical harness.
4. Using a phillips head screw drive remove the (4) screws that hold the headlight trim bezel. Careful remove the bezel from the headlight assembly. You may need to wiggle it out so be careful.
5. Remove the 10mm nut from the headlight motor shaft.
6. Carefully pry the linkage arm from the headlight motor. BE CAREFUL. You will need a long screw drive or pry bar to gain accress to the linkage. Wiggle the linkage back and forth to get it to release from the shaft. TAKE YOUR TIME.
7. Now you can remove the headlight motor from the support panel. There are (3) 10mm bolts with nuts that hold the motor to the support.
8. Using a small flat screw driver remove the outer motor housing plate. You will notice a thin line separating the plate from the housing. Take your time and BE CAREFUL. The plastic can be very brittle.
10. Once you have the outer housing plate removed you can see the internal gears. You can now remove the old plastic gear from the housing. Pay attention to the direction of the shaft that runs through the gear. You will need to put it back in the same direction.
10. Once the gear is removed from the housing you can see the worm gear that drives the unit. Clean any trash or dirt from the housing.
11. After cleaning the hosuing you can now grease the worm gear. Cut a corner of the grease pouch supplied and aplly the grease to the worm gear and at the shaft base. BECAREFUL not to get any grease on the surfaces that will be reglued back together. Once greased you can no install the new brass gear. Besure to insert the linkage shaft correctly before glueing the housing cover back on.
12. Locate the pack of Epoxy included in the kit.
13. Fold the Expoy pack in half and then cut of one end of the pack off.
14. Carefully squeeze out equal amounts onto a small piece of cardboard or pice of paper.
15. Usig the supplied stick, stir the equal amounts together until the are completely mixed.
16. Using the supplied stick CAREFULLY spread the epoxy around the outer egde of the housing cap. Be sure to spread the epoxy around the ENTIRE edge of the housing cover. This will act as a seal to keep water and dirt out of the internal gears.
17. CAREFULLY place the housing cover onto the housing. Make sure you have the cover alignment correct. The epoxy will need at least 30 minutes to setup. If you have the time allow the epoxy to dry overnight before using the headlights. You are now ready to reinstall the headlight motors.
18. Reinstall the headlight motor back onto the headlight bar. Installation is in the reverse of previous instrcutions. Once installed you will need to manually lower the headlight motors to there closed postion. Then you can reconnect the headlight wiring and battery cable.
