Recently I had an issue with a tempermental headlight
motor.  When I picked up the car the headlight motor was
not active and a quick dismantle revealed the plastic
main gear (last gear before actuator) was missing teeth. 
I ordered a replacement gear and voila the problem was
solved.

Here 2 years later the problem resurfaced.  Turns out
the replacement gear was no longer round.....

I picked up the  metal replacement but after reading some things on it, the gear might not be my problem!!

My parts car has a good unit the passanger side that I need so for a quick fix I am going to install it on my car and then I will take apart the broken one and get it rebuilt and put on the shelf until it is an issue again!!

It's not easy to see but the plastic has sort of undergone some transformations in the past year. 

The largest diameter near the edges of the gear measures 2.115".  The smallest is 2.055".

Here's a bit better perspective.  What's wrong with this picture?

Cheers

Yeah...was talking about the issue I have with mine...gotta check the relay then the gears but it will go up and down with the hand crank so it atleast narrows down the problem!!

Kevin, sorry to be nit whitted at 1220am but you lost me dude!!

to be honest I'm not a hundered percent sure anymore what it's doing

It has been since the fall since I looked at. In the next few days I should be able to diagnose it properly and go from there!!

Kevin, I have a Dickman gear if interested...let me know

Brian

Charlie - sorry did not mean to confuse you but your description of what is happening may require further explanation for me to totally understand your headlight motor predicament.

Brian - I already contacted Rodney for a gear and a spare - in case the other motor decides to pack it in.  But thanks anyways.

Decided to open the left hand motor to check on some free play - It didn't seem to affect the performance except for the occasional delay going down but with new gears coming thought why not.  Turns out the rubber bumpers in the main gear were completely obliterated.  Other wise the system was in pretty good shape.

 Something interesting as a a side note...all the factory lube, which unlike the right hand motor, was all nicely loose and evenly distributed all over the gears and bearings.  The right hand motor lube was all dried and caked up in odd locations no where near the required contacts points and is possibly why the main gear failed in the first place.  My guess is the little rubber bits of bumper actually worked it's way around all the gears to push the grease around.  Makes me wonder about leaving some of this in both motors when I reassemble them.    Cheers

Talk about lucky.  As I was cleaning up, I pulled the electrical contacts out and off the rotor, one of the brush contacts came off.

I Did the same!! Out with the bad gear, in with my Rodney Dickman replacement and put it all back together!!

Then I took a sharp chisle and hit the lip just above the retainer clip on the shaft on four sides/corners. This expands that rim slightly and holds the retainer in place

I google videoed the process...Buddy Craig has 7 posts showing the rebuild process I found very helpful!!!