Steve,
Are you aware of item #45?
It is a knob that is depressed and then manually twisted to, or so VERY slowly, raise the headlights when the motor zonks out.
I'm not even sure this could be the cause of the bind, but so goes long distance troubleshooting.
There is a lot of cantilevered weight on that headlight bar. I'm not sure how easy it truly is to rotate by hand. Perhaps someone else has experience on that?
As the diagram below shows, there is really nothing but the 1/2 moon gear to get in a binding situation.
If is IS perhaps just too heavy to rotate manually as opposed to being jammed, THEN I would go back to the condition of the plastic gear.
Larry
you are referring to item #38 in this diagram, right?
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