How does one lubricate the headlight mechanism on a 968? I've done it on my 944s over the years, but I don't have the FSM for the 968 yet.

My problem is this: When turned on/off, the passenger headlight smoothly goes up and retracts. The drivers headlight moves in a jerky motion and takes a bit of time to get fully up or down. I assume that the mechanism needs some lubrication, but could there be other causes?

 

Help? Anyone?

 

Aaron, I just went through some headlight issues myself. "Jerky" motion? First thing I'd check is the tightness of the bolt that holds the lever arm to the motor. Among other issues, mine was a bit loose and allowing the arm to slip on the splines.
While you're doing that, pop both the heim joints off and clean and re-lube them. The white lithium grease in mine had turned into the consistency of dried bubble gum.
If that doesn't work, you may need to do what I did and pull the motor apart and clean and re-lube all the innards. The good news is that it is a quality motor and (relatively) easy to take apart and clean.
In the course of my issue, I bought another motor and I'm going to tear into it and do a "Headlight Motor R&R 101." Let me know if you need it, it may be further inspiration to get off my duff and do it.

 

As a PSA, I fixed the jerky headlight by taking the headlight motor apart and cleaning the contact traces. I found a good video on YouTube that describes the process.

 

My passenger side was sticking yesterday, so I'm guessing it's similar. Glad we're getting some more videos on the car to help us keep them running.

 

Both of mine go up perfectly. Only one goes down so. The other waits for a slight bump in the road, or a gentle nudge from my hand to retract.
I believe it's bucket is slightly cracked. However, as long as it goes up fine, not a major priority.

-Yogii
AKA 968 Novice

 

My relays were chattering like crazy, drivers side would not come up. I thought maybe the relay, but opened and it is good and clean and great shape, I looked up the price, holly smokes that is an expensive relay. If I was retired I would do a new board for these. Anyways saw that video and was like man I dont want to do that.

I just finished doing a bunch of wd40 on the ball joints, let it soak, ran the lights up and down a few dozen times, then let it sit for 30 min, came back, ran it up and down a few dozen times, let it sit in the up position, sprayed again both ball joints on each side, and came back 30 min later, did the up down about 2 dozen times and the chatter in the relay is almost gone, sprayed one more time and will next do some fluid film on them later today. The arm moves up and down fine now.

I assume the motor struggling against seized mechanics, was creating more load than the relay likes.

So before you rip everything out try the simple stuff first

 

Just did a test after all day soaking in wd40, no strange noises goes up and down fast now.

 

FWIW, There’s no lubricating component of WD40. It evaporates. I’d get some lube on the moving parts if I were you. I used Wurth SIG 5000 for the heim joints and Boeshield T9 for all the other moving parts. I haven’t touched them since I rebuilt/replaced the motor above in 2010. .

 

Thanks, yes am going to add fluid film. Been using that on my trucks retractable side steps.

 

Just finished the fluid film thing, ran it through its paces. Snapped the lights back in and work even better than when I first got the car ages ago.

Question for the group in general, anyone ever lube/clean the armature for the headlight itself? Its tucked away pretty good, you would have to remove the headlight itself and maybe get under there. Because it is hidden away I suspect it is less likely to get crap all over it.

 

Check around for the R&R on going manual. IIRC, the armature is accessible if you de-couple the light from the motor and roll the light all the way forward.

Might be in the manual re: changing headlight bulbs. IIRC, you pull that triangle shaped handle towards the center of the car and it unlocks it.

 

The workshop manual call for removing and lubricating the small link arms with the ball and socket ends that attach the bucket to the motor. There are small spring locking clips on each socket. Remove the clips, remove the link, clean out old lube, put in new lube and reinstall all removed parts. The overly complicated mechanical headlamp relay will make a racket if it is trying to push through sticking parts.