I had a nonfunctioning right headlight on my '88. I got the kit with the metal gear and new bushings. Now that it has been replaced, the headlight only goes half way up. To be more specific, it will go all the way up with the hood raised and has no down force on it from the headlight cover. When I close the hood, it will stay up, but when I cycle the lights up and down, it only goes half up. Is there anything I should look for straight away?

The 88 headlights work on current drain. If there's too much current (caused by a jammed motor) the module will shut off the juice.
Something is causing too much friction.
The only time mine did this is when I had a cracked (plastic) gear that was binding. Obviously you don't have a cracked gear.

Did you lubricate the gear teeth with a little bit of bearing grease?
There is also a tension adjustment. I forget where it is, though. Been a while. On the bottom of the motor, IIRC.

[This message has been edited by Raydar (edited 07-15-2013).]

Yes, I did lubricate the new gear. I'll check the adjustment on the tension. It is in the bottom. I had my suspicions. Thanks

I had disassembled the motor before I even ordered the kit. During the disassembly, I noticed a small ball bearing. Not knowing where it came from I put it in the little tin for small parts. I was looking at the instructions the other day and noticed a warning not to lose the ball bearing. I put the little bugger back in and ouila, the headlight now has full range of motion. Lesson learned. even when you think you know what you are doing, take a peek at the instructions anyway.

Thanks guys.
My 88 is doing the same thing on the RH light. Have the rebuild kit, just need time to get to it. (Of course since I got the kit I haven't had the problem!)