Removing the headlight gear assembly

15 years ago I replaced the white plastic gear with the brass gear that is the same as the window regulator. I don't remember all of the steps however if I figured it out then I am sure you can. Good luck!

Fred,

Remove the wires from the motor and the limit switches.

Remove the bolts that secure the motor and the regulator to the side panel.

Using your hand, grab the front of the headlight bucket, and raise the headlights. Prop headlights in open position. This allows the long curved slot in the sector gear to clear the manual raise/lower shaft.

Remove the assembly from under the car.

In some cases, you may need to remove the forward limit switch.

John

Thanks John:
My lightbulb went on with your comment to remove the three bolts holding the regulator to the side panel. I could not see that the regulator was a seperate unit from the side panel - it looked like a single unit.

Just some comments for future surfers:
* Do not cut the crosstube!
* Do not attempt to lower or raise the lights by wrenching on the crosstube!
* I did this from the bottom of the car with the drivers side wheel off.

1) With the headlights in the down position, remove the two forward bolts that hold the regulator to the side panel. There are three bolts - two towards the front of the regulator and one at the rear.
2)If the headlight raise and lower mechanism still works - raise the headlights and then disconnect the battery. If not use the hand crank mechanism. This gets the long curved tooth gear on the crosstube out of the way.
note: motor rotates clockwise to raise. GND on white, + on black
3) Now there is access to remove the third rearward bolt.
4) The entire regulator is now loose.
5) Prop the headlight in the open position.
6) Unbolt the motor from the regulator and get it out of the way.
5) Document (for future re-installation) and then remove the electrical connections from the limit switches.
6) Remove the forward (or up) limit switch. The switch gets in the way of pulling the regulator out from the bottom.
7) Persuade the Regulator out.