c2 headlight motor installation problem

[Randy R.]

I am having difficulty installing the headlight motors, How can something so simple be so difficult? After many tries I finally got them in place only to notice that I was missing the plastic bushing that fits into the hole which accepts the bucket shaft. I have replaced the pot metal gear into which the rectangular end of the shaft is supposed to engage. Now I can not get the shaft to fit into the opening of the gear. What am I doing wrong?

The motors are originals, the gears and one of the shafts are reproductions. I do not remember having the bushings when I took everything apart long ago.

Thank you.

Randy

[Randy R.]

Re: c2 headlight motor installation problem

I checked the ID of the bushing and the OD of the shaft with a dial caliper. The measurements are probably not very accurate because of the difficulty of using the caliper in this location but the shaft is definitely larger than the bushing.

Randy

[Richard M.]

Re: c2 headlight motor installation problem

Randy,

Those plastic bushings should be the split type to self adjust the diameter.

Yes it's tricky to get the motor back in over the shaft and aligned to the flats on the shaft. With the motor in position, rotate the bucket up and down to help. Sometimes running the motor on the bench to get the gear slot in a better position can help. Another way is to turn the finger wheel, but takes longer.

Rich

[Frank D.]

Re: c2 headlight motor installation problem

Those plastic bushings like to jump out of place just when things get aligned. I take a swath of white lithium grease around the outer perimeter to give them a little more incentive to stay in place - doesn't take much.