87-88 Headlight Motor "Torque Pins" substitute

[Fierofool]

It has been many years (when I first got the Lil Duke Coupe) that I've rebuilt a Gen 2 motor.  I don't remember if it has the rubber weather seal at the top of the case, or not and if it does, I don't know if it would cause the effect you're seeing.  But if there is a seal, it might b outside the case rather than captured in its pocket. 

I agree with Pat that it's probably the ball bearing that's missing.  It's captured between the screw and the bottom of the motor screw shaft and any movement up and down would allow it to fall out.  That indicates that there should be no up and down movement.  The tolerance could have been upset if you loosened that screw and its locknut during repair. 

[Donster]

Good call by Pat and Charlie.
I took apart the motor and find out that the PO had already rebuilt the motor with the 3 pins, but the BB was missing!
This obviously let the shaft set down on the bottom in the housing, causing to much friction, hence the module cut the power.
I had no steel BB, so my friend who owns the garage/shop I use, found a little hard-plastic pearl, which fit great. He also held apart the the two connectors for me with 2 "L" shaped wires, while I inserted the shaft.
Seems to work fine now, but I will need to get the correct BB, as I don't know how long this plastic ball will last.

[GTRS Fiero]

I lost one, but found a ball from a bearing that was the same size ball.

[GTRS Fiero]

I thought of using a BB, but the size was a bit different, and it was either coated or made from a different material.  There were copper-colored BBs, and silver-colored BBs.  Possibly both steel core, but the silver-colored ones seemed to be zinc coated.

[TopNotch]

My home-made torque pins are already dead. Ordered some TFS ones today.

[Fierofool]

What is the diameter?  I have material that I have been using successfully in the Gen 1 motors.  It was a larger size than I needed so I put it on the shelf.  My material won't crumble apart. 

[Donster]

My motor stopped working again, so I took it apart and guess what? The plastic ball cracked in half, so there must be quite some torque going thru the shaft/spindle. Now I'm just going to order a refurb motor. They sell here in Germany for €80. €55, if I send in my old motor.
\D

[GTRS Fiero]

If you ever get something caught in the knob on top those motors, while the motor is running, you'll discover that there is a lot of torque.

[Fierofool]

If you would like to commit a crime and be sure you leave no fingerprints, just grab the knob when the motor's running, prior to the crime.

I have a motor that Montegut gave me.  It had been taken apart and I put it back together just to keep all parts there.  But the little ball bearing is gone.   

[TopNotch]

What is the diameter?  I have material that I have been using successfully in the Gen 1 motors.  It was a larger size than I needed so I put it on the shelf.  My material won't crumble apart.

A little over .4 inch, or 11mm.

[Fierofool]

I have lots of .380 and .390 if you want to try it.  It came out of Grainger and was supposed to be a smaller size.  Everything they had was color-coded as the same size.