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This is a guide to help replace the plastic headlight motor gear inside a 1986 Fiero. This will work with either the left or right side as they are identical, but I am changing the right headlight in the photos.
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Open and prop the hood.
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Disconnect the battery.
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Disconnect the headlight from its housing by removing the four bolts with a 10mm socket and wrench.
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Disconnect the headlight power cable that leads to the lightbulb, then remove the headlight from its housing to continue to disconnect the remaining wires.
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Disconnect the blue wire that leads to the motor, and the red wire harness that leads to the headlight relay.
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Move the headlight to a clean working space.
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Remove the headlight from the housing and remember or take a picture of the orientation of the arm.
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Remove the motor from the headlight and remove the three screws around the motor securing it to the headlight casing, and the screws on the motor arm.
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Use the 10mm for the screws on the casing and for the nut on the arm.
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In this step you will use the 1/4 Allen wrench to hold the arm screw in place.
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Remove the motor from the headlight casing and remove the last connection from the relay.
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Remove the arm with gentle but firm pressure, if the arm will not budge, hit it with a mallet/hammer to slide it off the rod.
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Now you will need to remove the cover, you should see screws all around the motor casing.
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Remove them using the 8mm wrench and Philips head screwdriver.
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(alt)If the motor is still factory sealed, take a 1/8th drill bit and drill through the rivets holding the casing closed.
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When removing the cover you should see two gears, on meatal, one plastic, and a metal lever in between.
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Remove both gears and the lever remembering their orientation or taking a picture.
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Clean out the plastic gear casing as it will most likely be covered in plastic shavings and dried grease.
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Clean the lever as it may also have what is left of a rubber spacer coating it and the residue will cause problems if left unchecked.
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Put new grease on a new plastic gear, then replace the old plastic gear in the motor.
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Put new rubber spacers in the far corners of the inside of the plastic gear.
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Put in a lever and make sure it fits snugly and once you do put the metal gear on.
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Put a resealing agent on the edges of the motor and close the casing again.
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When closing the case there is a seal inside the top of the motor casing. use needle nose pliers or a flathead to hold it in place.
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Do steps 1-7 backwards to reassemble and screws should come with the replacement kit if you took step 3 alt.
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To reassemble your device, follow these instructions in reverse order.
To reassemble your device, follow these instructions in reverse order.
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Austin Community College, Team 1-7, Kapoor Spring 2025 crwdns2935289:0Austin Community College, Team 1-7, Kapoor Spring 2025crwdne2935289:0
AUSTINCC-KAPOOR-S25S1G7
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