Headlight motors rebuilt

[strat10 25]

I had the dreaded winking headlights happen to me the other night. Drivers light pod would try and come up, but never would make it.

Pulled the motor out. Getting it out wasn't very hard. 

opened the motor up, and saw this....

 

Got a rebuild kit from here: http://rodneydickman.com/product_info.php?products_id=363 I didn't have to remover the actual motor, I was able to get the nylon gear out by using a vice, and a lot of wiggling

Nice kit.

 

 

 

 

Got everything back together!

Here is what I learned:

Drivers side: 

1. Remove the brace that holds the brake booster in place. It will save your forearm!

2. Replace the rubber stops for the motor arm near the front of the car. These were worn on mine, and it was catching the arm, causing the lights to stay up. I actually made my own.

3. You don't need to remove the motor/worm gear to get the old nylon gear assy out. It will come, just grab the spindle in a vice and wiggle,

4. Pay attention to the washers that come out.

Passenter side:

1. Much easier to get the gear Assy out. It slides out opposite from the drivers side.

2. Move the A/C condenser out of the way by removing the braked, also, slide the washer fluid reservoir up and out.

In general:

1. Take the time to clean out the pod drain. Mine were clogged, and made a headlight bath.

2. Take the time to adjust tighten the hinges of the pods. Don't make them to tight, and make sure your lights are not hitting the body of the car. (mine were)

 

Its a very fiddly job, but grab your 10mm wrenches and you should be good to go.

 

 

 

 

 

 

[Neil Potter 31]

I did this exact same job three weeks ago.  I couldn't believe how the motors had worked for so long with the powdered rollers in the gears.  Only one of my motors had stopped holding up the pod but the other was full of the same stuff. 

This was actually the easiest job I think I've ever done on the Esprit, everything unbolted with no drama, no injuries and the motors work fine now.  Also put some new rose joints on the push rods and cured most of the pod wobble at the same time, very satisfying.

I see you went for a metal gear wheel.  Did that make any difference to the sound of the motor?  Mine sounds a bit shrill now, although much quicker to pop the pods.