I've been trying to fix the headlights on my 1991 Firebird. They would go up and down only when they wanted to. Well, I took off the assembly and then opened up the motor. I've been hearing a lot of people saying how usually that plastic gear inside strips but I don't think that is the problem. There was too much play between the gear and the metal part that holds it so I made some "bushings" out of wooden dow rod. Everything is tight and turns much better now. As soon as the weather clears up I'm going to install everything back. Hopefully this will work. If it does turn out to be the gears, I might by some bronze ones or have a machine shop fab some up.

 

just get some nice fog lights... screw everyone else as long as you can see. They look better with the lights down anyway.

 

I have the factory fog lights and they work pretty well. I finished fixing my motors this morning and they work perfectly now. If anyone wants details, I'll do my best to explain. I wish I'd have a digital camera. Would make explaining a lot easier. But, for all who think the gear is the problem, that would definitely no longer be my first guess.