My headlight issue is no longer. After removing and checking out all the electrical and mechanical components of the headlight system, I reassembled and TAA DAA .. it works as designed. No repair/replacement of any parts. The only expense is bandages for the fingers and arm cuts from working in tight quarters with sharp edges.
The questions now are: why did it happen and how did it go away? As best as I can figure there was binding between the small drive gear and the sector gear on the headlight bucket shaft. The motor mounting plate is slotted for positioning. Gear engagement is critical. When I reworked things 3 years ago I didn't run the lights up and down manually to verify proper gear engagement .. I did this time.
So it works and the above is the best explanation I can come up with. The motor overheating was due to having to work very hard to raise the buckets. If its not that .. I got nothing. But it WORKS