Hey guys, one more question, got my headlights working again! Both pop up and light up just fine, however when i close them, my passanger side one shuts about halfway...(UGH!!!) i can press on it with my hand and help it down np, but it wont go down al the way itself. they are 86 headlight motors, is the motor going? or out iof adjustment? what do u guys think???
If you have to push on the knob, your limit switch is not making full contact through the downward motion. This can be debris in the motor itself, or even the seal at the top of the motor, right under the turn knob. I've seen seals that are swollen or dry rotted that interfere with the motor end play - which is used by the limit switch.
If this is all foreign to you, let me know. I'm not sure what steps you have gone through with your system.
Have you taken the motors apart to do a rebuild? If so, the limit switch may need cleaning, or as mentioned about the top rubber seal may not be seated in the correct position, not causing the limit switch to think the motor has hit full travel when it's only half way down. Have you tried turning the knob down through the spot where it sticks and see if there's any resistance there?
Sounds like one of the brushes broke off the spring arm. Once you have the motor out of the assembly, remove the small plate on the side of the motor and observe the brushes. If a brush is missing, your only repair option for that is to find another motor and use the brush set from it. This isn't a great picture but you can see the brush is missing from the right spring arm.
Ryan makes a good point about the rubber seal located underneath the knob, but it's usually not a problem unless the motor has been apart in the past. That seal is well captured by the two case halves and would be virtually impossible to dislodge without separating the case halves. It's something you do want to be sure to install properly if you do rebuild the motor.
If you decide not to tackle the motor rebuild, I provide a rebuild service. PM or email me for details if interested.