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86 Headlight Motor Rebuild

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kharmata View Drop Down
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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Topic: 86 Headlight Motor Rebuild
    Posted: 13 March 2011 at 6:45pm

Recently I had an issue with a tempermental headlight
motor. When I picked up the car the headlight motor was
not active and a quick dismantle revealed the plastic
main gear (last gear before actuator) was missing teeth.
I ordered a replacement gear and voila the problem was
solved.


Here 2 years later the problem resurfaced. Turns out
the replacement gear was no longer round.....


This gear was from the Fiero Store and I believe it too
be inferior plastic. It has since lost it's overall
round shape and even the teeth are no longer straight
axialy. they sort of curve (concave) from one side of
the gear to the other. I look forward to my metal
replacements from Rodney Dickman.
Kevin
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Nexus View Drop Down
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Post Options Post Options   Quote Nexus Quote  Post ReplyReply Direct Link To This Post Posted: 14 March 2011 at 6:14pm

I picked up the  metal replacement but after reading some things on it, the gear might not be my problem!!

My parts car has a good unit the passanger side that I need so for a quick fix I am going to install it on my car and then I will take apart the broken one and get it rebuilt and put on the shelf until it is an issue again!!

Charlie
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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Posted: 16 March 2011 at 7:44pm

It's not easy to see but the plastic has sort of undergone some transformations in the past year. 

The largest diameter near the edges of the gear measures 2.115".  The smallest is 2.055".

Here's a bit better perspective.  What's wrong with this picture?

Cheers

Kevin
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Post Options Post Options   Quote Dawg Quote  Post ReplyReply Direct Link To This Post Posted: 16 March 2011 at 8:06pm
Wow....that material is not very stable is it?  It looks warped.

I've said it before, one of the problems that plague us Fiero owners is the bad quality aftermarket parts out there.  Not so much the Fiero Store or Dickman stuff but the parts at the local automotive retailer.

We do our part but the components let us down.

Bummer.

The Dawg
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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Posted: 16 March 2011 at 8:16pm
Originally posted by Nexus Nexus wrote:

I picked up the metal replacement but after
reading some things on it, the gear might not be my problem!!



Obviously you are talking about another matter of your own here...?

Dawg. I will try and hang on to this gear for a show and tell at the
next gathering. Yes it is very deformed. More even than the picture
shows. Oh and some teeth are also chewed away.
Kevin
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Post Options Post Options   Quote Nexus Quote  Post ReplyReply Direct Link To This Post Posted: 17 March 2011 at 1:18pm

Yeah...was talking about the issue I have with mine...gotta check the relay then the gears but it will go up and down with the hand crank so it atleast narrows down the problem!!

Charlie
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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Posted: 17 March 2011 at 4:22pm
Charlie - you say your headlights go up and down via hand
crank of the motor but also that the motor runs
continuously when plugged in...? Are you saying the motors
are on and just stuck when plugged in or on and rotating
when plugged in? If on and rotating - then direction will
tell you what what part of the circuit to consider.
and that likely the main gear is stripped.
Kevin
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Post Options Post Options   Quote Nexus Quote  Post ReplyReply Direct Link To This Post Posted: 18 March 2011 at 9:20pm

Kevin, sorry to be nit whitted at 1220am but you lost me dude!!

to be honest I'm not a hundered percent sure anymore what it's doing

It has been since the fall since I looked at. In the next few days I should be able to diagnose it properly and go from there!!

Charlie
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Post Options Post Options   Quote Bassman Quote  Post ReplyReply Direct Link To This Post Posted: 18 March 2011 at 9:24pm

Kevin, I have a Dickman gear if interested...let me know

Brian

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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Posted: 18 March 2011 at 9:31pm

Charlie - sorry did not mean to confuse you but your description of what is happening may require further explanation for me to totally understand your headlight motor predicament.

Brian - I already contacted Rodney for a gear and a spare - in case the other motor decides to pack it in.  But thanks anyways.

Kevin
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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2011 at 6:43pm

Decided to open the left hand motor to check on some free play - It didn't seem to affect the performance except for the occasional delay going down but with new gears coming thought why not.  Turns out the rubber bumpers in the main gear were completely obliterated.  Other wise the system was in pretty good shape.

 Something interesting as a a side note...all the factory lube, which unlike the right hand motor, was all nicely loose and evenly distributed all over the gears and bearings.  The right hand motor lube was all dried and caked up in odd locations no where near the required contacts points and is possibly why the main gear failed in the first place.  My guess is the little rubber bits of bumper actually worked it's way around all the gears to push the grease around.  Makes me wonder about leaving some of this in both motors when I reassemble them.    Cheers

Talk about lucky.  As I was cleaning up, I pulled the electrical contacts out and off the rotor, one of the brush contacts came off.

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Post Options Post Options   Quote Nexus Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2011 at 8:19pm

I Did the same!! Out with the bad gear, in with my Rodney Dickman replacement and put it all back together!!

Charlie
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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2011 at 8:26pm
Tis the season. 
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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2011 at 8:31pm
Charlie - I am curious - how did you re-secure the main gear retainer?
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Post Options Post Options   Quote Nexus Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2011 at 8:48pm

Then I took a sharp chisle and hit the lip just above the retainer clip on the shaft on four sides/corners. This expands that rim slightly and holds the retainer in place

I google videoed the process...Buddy Craig has 7 posts showing the rebuild process I found very helpful!!!

 

Charlie
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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2011 at 8:57pm
The bumpers are easy - just curious what you did for the retainer.  thanks.
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Post Options Post Options   Quote Nexus Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2011 at 9:19pm
hope it helped!!
Charlie
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Post Options Post Options   Quote kharmata Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2011 at 9:25pm
My plan was to center punch the retainer. Either way I suppose.
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Post Options Post Options   Quote Dawg Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2011 at 11:49pm
Wow....chewed or what?  It appears as though the motor has not stopped in time and cut the teeth right off.

I would check the limit switches to make sure they are in good shape and in the right place.

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