1991 Formula Headlight motor Problem
 

About a week ago, I turned up my headlamps (to clean them) and found one of them had a weak lite (right side). I went to PepBoys and bought 2 new replacement blubs. In taking out the unit, I noticed one of the prongs was slightly bent. No big deal, I screwed all the pieces back in the lowered it down. The next day I just flipped up the switch to move the lights up and down to make sure everything worked.

Next time I hear a whining sound that continues for about 4-5 seconds after the lights are down. Even when I raise the lamps, it makes the same noise. Then I notice that the left side is going up and down, but not making it all the way up. Finally it does not move at all, but every time I turn them on, the noise comes on.:rofl:

Also what is weird, is that I always used the parking lite switch to just have the parking signals and stop lites stay on when I was driving. Now the headlamps want to go UP when this mode is used. Any ideas as to what is going on. I could take it to a Pontiac Dealership (I know GMC/Buick), and have them check it out, but the parts may not be made anymore. I checked out eBay, but they only have several units that fit the 93-97 design.

If anybody is good at doing a diagnosis on my car and could repair it, I would pay you for your time and parts. ANY HELP WOULD BE WELCOME!

I think there is a little nylon puck (for lack of a better term) in the gear that dries out and turns to powder after a while, or the gear strips the teeth. This place has all the parts you could need, but I think //<86TA>\\ used a little nut in place of the nylon pieces. You're going to need to take the motor apart and see what is the problem.

Here is the link to the nylon replacement pieces

If the headlight motor is similar to the 4th gen, sounds like a stripped gear. The 4th gens only use half the teeth on the gear so the cheap/temporary fix is to disconnect the arm from the motor and spin it so you are on the other half of the gear.

They are different then 4th gens. Polarbears link is what you need

You should be able to replace the gear w/a brass type unit to avoid further issues. Both are available from hawks. After awhile the teeth in the gear becomes brittle and breaks.

http://www.hawksthirdgenparts.com/ca...26-Components/

Pretty sure Hawks gets them from TDS and it is cheaper than Hawks.

Sounds like a bad gear for sure. I have replaced them with the brass ones and they work very well.

Any idea as to where you got the BRASS gears?

By the way guys, thanks for all the help and offers to check out my problem. ED

Its within the link that Polarbear put in his first reply to your question ...

http://www.top-downsolutions.com/Bod...-aluminum-gear


and if you were to need the brass gears i would really be surprised. Most common that i see is the crumbling inserts. Put new ones in and worry about them again in 20 years

Tore down the motor and sure enough, bunch of dust came out. Gear and everything else looked good.

Just wanted to say a HUGE thanks to Brian for his help with this project. As uaual it was Murphy's Law that kicked in, but his expert understanding of how to fix the problem saved the day. I ordered the parts from TDS (both side kits) and hope to be back in business again soon. Now when I use my headlamps ONCE a year, I'll be good for the next 23 years.:lol:

No problem Ed. Let me know when the parts come in to finish the job.

Brian just finished the install and did an OUTSTANDING job for me. The lights work perfectly and now the parking lights work WITHOUT the headlamps popping up. It's really a pleasure to have people that have awesome work ethics and do something in a professional manner. :bow:

Happy to help and glad everything worked out well. Have fun at the show on Sunday. In the meantime, I will be wrenching on my car with little chance of success. :)

He's the man when it comes to anything lighting.