C5 headlight adjusters (nylon gears)

[SuprSi]

I'm doing a headlight refurb soon, fitting new projectors Trups supplied, I want to get before / after pics but the headlight alignment was a bit pants, I've gone to set them right and ALL of the bloody nylon gears are slipping on the knurled shafts.
I've had a quick Google search and found nothing, are the nylon gears available on thier own? I've tried epoxy, that failed miserably.

CheeRS

[Trups]

Is that on the outside its slipping? Where the plastic meets the metal coming from inside?

Trups

[SuprSi]

Hey Trups, Yep that's the bits. Whoever had it last bodged one by winding an 8mm nut on but now the other 3 are slipping too

[4everRS]

I don't check the site that often, but saw this and thought I'd share what I did.

The nylon gears are prone to failure.



Remove the gear



Carefully drill a tiny hole in the end of the knurled pin



You'll have to hold it so it doesn't push in



The hole is needed so you can tap a tiny screw in the end to be able to hold the knurled pin out. Carefully put jb weld in the hole on the nylon gear, and slide on the pin. As your doing so, you'll have to get your screw or nail ready to go on the drilled hole and pull the pin outward, sliding the gear on further.

Let dry and your done. And still adjustable.



That or buy a new headlight.

[SuprSi]

Thanks 4everRS,

That's more or less what I did, although without pulling on the shaft. I might have to try again with your method. It's a pretty stupid design!

[bam_bam]

Thanks 4everRS,

That's more or less what I did, although without pulling on the shaft.

*snigger*

[SuprSi]

Lol, trust you! That is quite funny tho. xD

[4everRS]

Thanks 4everRS,

That's more or less what I did, although without pulling on the shaft. I might have to try again with your method. It's a pretty stupid design!

Yeah, it's really important to be able to pull that pin outward while sliding the gear on. Mine's been holding great for several months now.

[R5XVB]

Slight tangent but related...

I replaced my headlights with 'Angel Eyes' on a 4BH Allroad, the self levelling motor connectors (electrical) were a different size and as I noticed later three wire versus four wire. Not bothered, I thought removing the dash error message would be a breeze as the loss of thus function was no biggie. How wrong was I? You can't delete it...

So thought ok reconnect the old motors and hide them away, oh yeah that's right yesterday was bin collection day. Muppet. So my options are to splice the wires over the correct resistance or source another set of these levelling motors. Anyone got any or know what resistance is needed to pretend to the system that these motors are still physically present?

Cheers...

[SuprSi]

You could try 100ohm resistors, that will mean ~140mA and nearly 2 watts, you'll need the ceramic type as they'll get a bit warm.

These can cope with 5 watts so will be perfect.
http://www.amazon.co.uk/Radial-Ceramic- ... B00857S6YM

[R5XVB]

You could try 100ohm resistors, that will mean ~140mA and nearly 2 watts, you'll need the ceramic type as they'll get a bit warm.

These can cope with 5 watts so will be perfect.
http://www.amazon.co.uk/Radial-Ceramic- ... B00857S6YM

Ta muchly.