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Old 05-23-2007, 04:05 PM   #1
Oceanair
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Join Date: Apr 2006
Location: San Diego
Posts: 34

1996 SC2
Default Headlight Actuator Gear Replacement

I just finished replacing the stripped nylon actuator gear on my left headlight of my SC2. I initially was going to replace it with a brass gear that is available for approximately $45, but decided that the Napa Autoparts nylon gear would do just fine at a cost of $11. The Napa part number is BK6652137.
The hardest part of the entire job was removing and reinstalling the motor to the headlight assembly. It took me approximately 30 minutes to remove and 30 minutes to reinstall the repaired motor. The reason I went with the nylon gear is that my car is a '96 and I figured that it lasted 11 years so another 11 years will probably see either me or the car in a graveyard.
In addition to the adhesive recommended to reseal the gear housing, I used a generous amount of Marine Tex (like JB Weld) to overlap the seam to relieve some of the strain on the resealed seam so hopefully it will not pop apart. I clamped it together and let it dry overnight. So far, it works like a champ. It sure beats getting a new actuator, or going to the wrecking yard and getting a used one that possibly won't work.

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