Headlight Motor Gear Removal
 

I printed directions from here & they seem to be a little backwords from my headlights. Or I could be the one that is backwords.

Anyway, I'm stuck. I have the headlamp out, the motor cover is off, I blew out all of the white greasy powdery crap but I can't pull the gear out.

The directions I have say to punch out the pin on the other side of the motor. I've been unsuccessful in doing this. However the picture from the directions looks different from my set up at this point.

If any of you can take a look at this picture & tell me where to proceed from here I would greatly appreciate it.

http://i88.photobucket.com/albums/k1...light_Gear.jpg

Thanks

I did this to my 89 several years ago, and I honestly don't recall having to punch the pin out. But I could be wrong on yours. From your picture it almost looks like there might a snap ring holding it. Hope this helps.

Joel

No snap ring visible from the side the picture is take from. I don't want to pry on the gear & mess it up either. Also there is not enough to get plier on to pull the gear out.

Still searching for the solution.

This is from a 91.
I had to yank the thing out.
Your looks a bit different though.

http://i145.photobucket.com/albums/r...kvtwin/hl2.jpg

http://i145.photobucket.com/albums/r...kvtwin/hl4.jpg

http://i145.photobucket.com/albums/r...kvtwin/hl3.jpg

I did mine 2 years ago and you do need to remove the pin to get the disk with the shaft out. If you need to you can turn the motor with the knob to get it in a better position to knock it out. Not hard once you do one. Good luck. Robert

Thanks
 

Thats what I was thinking. I need to buy a good punch set.

Mine looks opposite of the 91 listed above.

Thanks for the feedback.

How hard was it to remove the pin?

How much pressure did you have to apply?

The directions from CF said that it did not require much effort. I tried to tap it out with a small hammer & allen wrench with no luck.

I'm going to get a puch set tomorrow to give it a try. Thanks for the feedback.

Just did mine with my dad two weeks ago. Take the motor off - two bolts. The shaft that goes down to the gear from the motor is what's keeping you from pulling it out. Be careful with the two bolts holding on the motor - we snapped one on each side, that was fun. Just go slow....

I just did my left headlight, and I had to remove the pin to pull out shaft from the motor. You will need a 5/32 punch, I bought one at Sears, you need it.

Here is link I used and worked perfect!
http://home.comcast.net/~zrjuan/headlight.html

headlight motor
 

THIS IS WHAT YOU DO !!
Loosen screws holding motor to gearbox
Loosen nut on threaded rod that has a slot for a flat screwdriver.
Then turn threaded rod about two turns--this will relieve pressure on gear and it will come out. THIS WILL DO IT !!