Headlight adjustment knob weirdness

[PhotoBone]

I have something weird going on with my headlight adjustment knob. I don't know how it got this way but the mid point of adjustment seems to have rotated counterclockwise. The photo of the knob with the dot at 9:00 is as far clockwise as it will turn. I think it used to go up to around 11:00 or 12:00. The photo with the knob turned counterclockwise is how far it goes before it stops. I believe this is a good bit farther than it's supposed to go. I've pulled the knob off and the insert on the inside that secures it to the post doesn't move so it isn't that the plastic knob has moved on the post. It appears the post the knob goes on has rotated its center point counterclockwise. How could this be?

At the same time I'm having trouble with the headlight adjustment motor. When the adjustment knob is turned all the way left or right the motor doesn't stop but makes a knocking sound that is from the plastic gears slipping on each other. I've pulled the motor out and seen this happening. I assume the motor needs to be replaced. Note that the adjustment knob rotation weirdness is unaffected by having the motor pulled out. I don't know if one is related to the other or if there are two separate problems here. Any ideas?

 

[Obo]

I can't speak to the motor issue, but when you pull the knob off, is there a hex/octagon locking ring that you can see?

I'm wondering if the whole switch assembly is loose inside? I can't tell if it's just attached to or if it's soldered onto the circuit board along with the light push buttons to the right. It appears to access it you have to remove and disassemble the gauges.





The service manual has a step by step procedure to test the knob, wiring as well as the motor if that helps.

 

[Catmandu2]

Your headlight motor is shot. I have an '04,, and had to change mine. It had the same symptoms. Also,,, my control knob rotates as far as yours does. There are write-ups on changing and adjusting the motors,, here to be searched out and read. The motor is easy to change,,, but hard to get to. I did it when all my tupperware was off. Do yourself a favor,, and install a set of F2 led's while you are in there. You won't be sorry,,, cheers,, CAt'

 

[PhotoBone]

Obo and Catmandu2, thanks for your responses. I’ve ordered a new motor and a new adjustment switch since it wasn’t an expensive part. I’m going to replace them both and will report back here with the result.

 

[magnus]

I'm having something similar and trying to remove the dash and headlight knob. I have the dash off but can't seem to remove the knob.

Is there some mechanism holding the knob on the shaft or is it just glued on? How do I remove the knob to pull the pack of the dash off?

TIA.

 

[magnus]

So I figured it out. Leaving some pics here for the community.

- the knob is designed so that the dot sighs face approximately downward (6 o clock) at the mid position(position 4or5 out of 8). The plastic knob, metal ring inside it and the motor shaft have keys so that the knob can't be assembled any other way wrt to the pot. The pot itself can only be aligned on way in the dash with the hole in the white plastic piece.

- the knob is just worked off gently by pulling .

Some pics

 

[PhotoBone]

Your headlight motor is shot. I have an '04,, and had to change mine. It had the same symptoms. Also,,, my control knob rotates as far as yours does. There are write-ups on changing and adjusting the motors,, here to be searched out and read. The motor is easy to change,,, but hard to get to. I did it when all my tupperware was off. Do yourself a favor,, and install a set of F2 led's while you are in there. You won't be sorry,,, cheers,, CAt'

Catmandu2, you were correct. The motor was bad. Seems to work fine now. Thanks!