Headlight Motor Manual Knob

[whalenlg]

My popups didn't pop down last night - probably one of the brushes in the motor is bad.

My manual knob on top of the headlight motor just spins. The hex part to engage the hex motor shaft is gone.

But given that my in car tool box doesn't have a tiny socket or wrench, I was kind of stuck. Plus the motor was really hot, so I pulled all the fuses (3) until I could get home and sort it.

Anyone know where to get a new knob?
Are there 3d STLs to make one that anyone knows about?

Thanks!

[Tom]

I don't think plastic would hold up unless you added some kind of metal insert to engage the shaft in the motor. Maybe ask around if anyone has a dead motor with good knob? More often than not when this happens, 'something' is catching on the headlight, causing it to get stuck and then blow fuse 16. Normally you can check for obstructions with the knob, but until you sort that out, I'd check fuse 16 to start.

[whalenlg]

Hi Tom - the original is plastic, so year, 38 years later its worn out! Not sure which flavor of printed material is better.
The 3 fuses were all good and the relay as well. Checked all voltages coming to the motor with the ignition and light switch. All OK.
I put a 6mm socket on the shaft , moved the lights down a bit and then everything went back to normal.
Just looking for a way to fix it when I don't want to open the toolbox....

[Tom]

I should have been clearer. I meant that typical FDM 3D printing plastics don't hold up well on keyed shafts like that. There are certainly plastics that are strong enough, including some printable resins.

So is everything working again?

[whalenlg]

Yes - I just moved the lights down with a crescent wrench on the shaft to get started and the motor kicked in as was fine.
Ordered this on amazon as I think the hex socket should fit the shaft hex which is 6mm/ 1/4":
https://www.amazon.com/dp/B013GK9I3A?ps ... ct_details

[Iraferd944]

I just loosened the nut on the linkage and slowly pushed the lights down… but in saying that I haven’t been able to repair em yet. I just manually tighten or loosen the nuts and push the headlight up or down…

[Tom]

I just loosened the nut on the linkage and slowly pushed the lights down…

Brilliant!