Headlight Motor Removal, Cleaning, and Installation

Introduction

If the headlights cycle up and down continuously when operated, the most likely cause is a dirty electrical contact wheel inside the headlight motor gear assembly. The cycling typically occurs when moving from the raised to the lowered position, but can also occur in the opposite direction.

The contact wheel provides a continuous electrical path to keep the motor energized. Two small plastic inserts in the wheel interrupt the electrical contact at the full-up and full-down positions. Over time, corrosion builds up on the wheel and migrates onto the plastic inserts, giving them enough conductivity to keep the motor energized past the intended stop points. Cleaning the contact wheel corrects the problem.

Tools

• Metric wrench/socket set
• Steel wool, emery cloth, or fine-grit sandpaper (see procedure — 440 grit preferred)
• Flat-tip screwdriver

---

Headlight Motor Removal

1. Disconnect the battery.

2. Disconnect the headlight motor electrical plug and remove the relay.

3. If the motor has a manual raising/lowering dial, rotate the headlight to the 1/2 to 3/4 raised position to make all motor mounting bolts accessible. (Some early cars do not have a manual dial.)

4. Remove the two lower 10 mm bolts holding the motor to the mounting bracket.

5. Lower the headlight back to the full-down position to preserve the motor-to-linkage alignment during removal.

6. Remove the 13 mm nut from the end of the drive shaft (which holds the headlight linkage to the motor shaft).

7. Remove the remaining (top) 10 mm bolt holding the motor to the bracket.

8. Use a flat-tip screwdriver or pry bar to separate the linkage from the motor shaft. Remove the motor.

---

Cleaning the Headlight Motor Assembly

1. Remove the rubber boot that covers the bottom of the motor and gear housing. Work it down off the motor, around the bottom of the gear assembly, over the drive shaft (the hardest part), and off the relay block. Work slowly and carefully to avoid damaging the boot.

2. Six flat-head screws hold the gear assembly cover — five are visible, one is hidden under the relay block. Note the position and length of each screw before removing; they are different lengths and must be returned to the correct locations.

3. Remove the two screws holding the relay block in place (one long, one short). Move the relay block aside and remove the screw underneath. Remove the remaining three screws.

4. Remove the gear assembly cover carefully — there are electrical contacts on the back side of the cover. A small ball bearing is located in the center of the contact wheel; remove and set it aside so it is not lost.

5. The contact wheel is now visible. Two plastic areas (non-conducting inserts) and several plastic tabs holding the wheel to the large gear behind it will be visible.

6. Clean the contact wheel with steel wool, emery cloth, or fine-grit sandpaper. 440-grit sandpaper is preferred; if only 220-grit is available, use a light touch. Blow all debris out of the gear assembly after cleaning.

7. Reinstall the gear assembly cover and relay block. Confirm each screw goes back into its correct position (lengths vary).

8. Reinstall the rubber boot. Place it over the relay block first, then work it slowly over the gear assembly. The hardest point is getting the boot over the gear assembly drive shaft. Insert two fingers inside the boot on either side of the shaft and pull the boot up and over — this may take several repetitions to "walk" the boot into position.

---

Headlight Motor Installation

1. Before installing the motor, attach the relay and electrical plug and set the motor on top of the washer reservoir (or another stable surface) with the drive shaft not touching anything. Temporarily reconnect the battery. This resets the motor back to the fully lowered position in case it moved during cleaning. Disconnect the battery and electrical plug/relay again before proceeding.

2. Install the motor to the mounting bracket. Install the top 10 mm bolt and the bottom front bolt (do not fully tighten yet) without disturbing the linkage. This ensures proper motor-to-linkage alignment.

3. Install the 13 mm nut holding the linkage to the motor shaft and tighten.

4. Using the manual dial on top of the motor, rotate the headlights to the 1/2 to 3/4 raised position to access the bottom rear mounting bolt (10 mm).

5. Tighten all motor mounting bolts and lower the headlights to the full-down position.

6. This is a good opportunity to lubricate the headlight linkage.

7. Plug in the relay and motor electrical plug.

8. Reconnect the battery.

9. Test the headlights for proper operation.