Every post on this board about the headlight motor gears and "clutch" assembly for the motor is the same, they take apart the headlight motor, pull out the gear and its full of mushed up plastic parts, that used to be some sort of "clutch" or "shock obsorber" or something like that. But everyone seems to say they see the same thing, mushed up plastic. What IS SUPPOSED to be there, its obviously not steel ball bearings, and i doub't it was plastic ball bearings. But i do know their purpose was to act like a clutch when the headlight was all the way up. does anyone know or have picture of what is supposed to be there? I want my headlight motors to act like they are supposed to, not just gluing the gear to the output shaft.

 

Breathment, Just get you some nylon or teflon or other plastic rod, the size being whatever fits closely to the cogs. Cut to a length that will allow the assembly to go back easily. Chamfer the ends for smoother operation. Probably there's some existing grease left over on the housing somewhere. I'd maybe coat'em with it. Good luck

 

And another thing. When you go to reasemble the motors. Turn your headlights to the on position and prop them up . Mount your motors, then turn the overide ***** till the motor arm comes into position for the headlight assembly. Pop the motor arms back on , Then flip your headlight switch to the off positon .Don't forget to remove the props though. The lights should pull down and everything be in sync. As far as the plastic parts being cluthes, I think they are more of dampeners than anything. Either the motor will only spin the arm so far or there is some kind of resistance feedback that switches them off. Good luck again!

 

alright, i got it put together using ball bearings, and it actualy did work kinda good. they did act like clutches, size was 5/16"

thanks

 

I never thought of the mushy stuff as a clutch. I thought it was there to keep the plastic gear turning evenly with the metal piece. I chose wooden dow rod instead of the ball bearings and it's been holding up pretty well so far.