I have recently noticed that it is taking a slight longer bit of time for my driver's side headlight to flip up.
On a few occassions, it has not opened at all. I turn the switch on and off, but no use. Then I go out, and try to pull up (lightly) on the light. It comes open, but then flops back down again. If I do this a few times, it seems to stay up and then work correctly for about a week, and then does it again.
The really weird thing, is that when I turn the headlights off, and then the ignition, I can hear the driver's side headlight motor whinning like it is closing. But it is already closed.
I am thinking that the motor gear is getting stripped-out(?)
How do I fix this???

 

The gear on your 1987-92 style headlight actuator isn't stripped out. What is (or was) inside of the large nylon gear IS. Take a look at the headlight repair kit I manufacture and you'll understand what is going on. Short answer; these headlight motors are load-sensing. They shut off when the relay senses the headlight bucket has hit the stops (either upper or lower). Since the OEM hard gel inserts inside your gear are bad, the motor will continue to run. Replace the crumbled inserts with the CNC machined Delrin bushings from my kit and your problem will be solved.

Lon Salgren
Top-Down Solutions

 

Sorry I never replied with the results. Your kit was fantastic!!! I ordered the kit, like you suggested. I followed the instructions, and (of course) broke all the original screws, removing them. So I had to drill them out. After a few needless purchases, I bought Cobalt bits, that chewed through those broken screws like butter. If you are attempting this, do not waste your money on titanium bits, and/or screw extractors, just get the cobalt bits. I used stainless button-head screws to help cut new threads into the soft aluminum housing. Overall, I was very pleased with the outcome, but wish I had not wasted money on those junk titanium drill bits, and the screw extractor set.
Just figured anyone else who might be starting this project would appreciate a couple pointers.