mjensen

I am a new owner of a 84 928s, I bought the car knowing that the headlights were disabled because the owner was not sure/did not want to fix the problem. I first noticed that in the engine compartment, on top of the h/l motor I can manually raise and lower the headlights by winding the **** on the top. I then proceded to put the fuse in that was missing, turned the key and the wotor was only spinning the ****, without the lights raising/lowering and the lights did not turn on. Any ideas...

rixter

check these before proceeding
relay XIX-XX headlights
also fuses 24-27 control h/l beams seperately for each side

SharkSkin

There is a short piece of metal with plastic bushings on either end. One end attaches to the crank on the side of the motor, the other attaches to the crossbar that moves the lights. Make sure this short piece is attached properly with BOTH e-clips -- it can come loose and poke a hole in your radiator. See item 21 in the pic below(Thanks Tony):

mjensen

Thanks for the help. So far the linkage #21 seem correct, all clips and bushing intack. Fuses 24-27 are also ok. Fuses 19,20 are out, 19 is the one i installed to attemp to raise lights.How can I test the relay? Is there a pin/keyway on the gearbox-side of the motor that would allow the motor to turn but not drive the linkage? I need to invest in a good manual...

SharkSkin

The Workshop manuals are available on CD or, while supplies last, the Big 3 all have screaming deals on the full set in binders -- just over $200. That's about $1000 less than Porsche wanted for them a year ago IIRC!

There is no keyway on the shaft. I don't think they changed much over the years... on my '78, there is a tapered shaft with ridges(not quite splines) coming off the gearbox; the crank arm attaches to this with a nut. If the nut is loose, the shaft would just spin.

What I find baffling is that you can raise and lower the lights with the **** but the motor just spins when you try to do the same with electricity. Maybe the shaft is just loose enough to slip when moved with force(by the motor) but not when moved gently(by hand).

jpitman2

The motor drives a worm and wheel reduction, and the output wheel has a shaft that at best could be described as knurled to grip the output arm. I would try holding the output arm (connected to headlight lifting cross shaft with the clipped link) while the motor is running, and see if you can feel the shaft tunring inside it. I doubt this, as the on/off contacts that tell the relay "lights are up you can turn on the bulbs now, and stop the lift motor" are on the worm wheel inside, and if the motor keep spinning it isnt seeing any change in these contacts. I suspect the worm/wheel is stripped or something similar. When I got mine the lights would not lift by switching, and it was just the relay.
jp 83 Euro S AT 49k

mjensen

Thanks guys, I have narrowed the problem down a bit. I can now turn the dash headlight switch on, mutor spins, I manually turn the motor linkage bar(#8), headlights raise, motor stops. I can then turn headlight switch to off, lights lower with no assistance, lights turn off, motor stops. I am assuming the motor needs to be replaced. Also I found all three 10mm bolts that mount the motor to the frame loose, attempting to adjust location...

John Struthers

If you can move the lights (that's plural, right?) up and down manually the clamp toward the ends of the shaft is tight, the actuator seems to be connected correctly with cir-clips in place and therefore the bar is not slipping, nor are you punching a hole in the radiator due to a missing clip. If the lights turn on/turn off and the motor is spinning then the switch, relay, and motor seem to be O K.
I'm not sure about the loose hardware...
There may be an issue with the ****.
By **** are you talking about the knurled **** on to of that can shaped device that may or may not have a large rubber boot around it? If so the **** may have been turned to far in one direction or another -it is after all and adjustment ****.
FWIW
While doing an abnormal clean-up under the hood one day I found myself claning this very **** and it's surrounding area.
The next day I had issues similar to yours with the headlights.
Unfortuneatly, -if memory serves- the damn thing didn't seem to have a stop!
Which means it can turn continuously in either direction. I played with it in 90 and 180 degree increments till it worked.
Good luck!
P.S.
There is a real thin description in the owners manual .

SharkSkin

John, what year car are you referring to? On my 78, that **** is used to cycle the lights manually....

jserio

Hey M, If you headlight motor is bad I have one you can have for a few buck plus shipping. It is tested good. It is from 85 model year but I don't think there was a difference. If it is let me know.

mjensen

Yes, I would be interested in the motor...let me know how much. The **** on the top of the motor turns indefinitely, no stops. Is it possible it needs to de indexed/timed justby turning the top ****?

SharkSkin

I just double-checked my 1978 owner's manual. That **** on the top of the motor is for cycling the headlight mechanism manually. It is in no way intended to be an adjustment/index/etc.

My observations fit this... When all is working normally, give this **** several turns with the key off. Then turn the key, and the headlights will go up, then back down and park in the normal position.

John Struthers

Dave,
Yep, thats what that **** is for but for some reason when I asked about a similar situation
-years ago- Iwas given the same info you are giving...It didn't work!
That's when I noticed there was no stop -left or right- for the ****.
The only two things I did differently was 'play' with that ****, and trickle charged the battery overnight.
As you say yourself "give the **** several turns with key off. ...."
Have you tried cyling the **** in the opposite direction?
I would think if there is no stop and you can cycle the motor/gear/actuator to raise the lights in one direction I should also be able to do so in reverse direction???????
I have noticed that when the battery is extremely, low the lights stay up.

SharkSkin

I'll have to give that a try. I have the rubber boot on mine so it's a bit of a pain to get to, but I'll take a look when I have a minute.

mjensen

I have also turned the **** in both directions, raising and lowering the lights. If I raise them manually in either direction I can them power the lights off/down and the lights will turn off , return to the down position and the motor will stop...