a helper was waitin' for me here...

With 8 legs, he oughtta' be better than a power tool!Hope he's not all thumbs like me!

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THERE ARE EDITS THROUGHOUT THIS THREAD, WHERE I FOUND OUT A TRICK, OR BETTER SEQUENCE FOR PROCEDURE.

FIRST REMOVE THE ENTIRE ASSEMBLY.(SEE POST #5) I WOULD ABSOLUTELY FOLLOWTHIS PROCEDURE - YOU HAVE EXTERIOR SURFACES ALL OVER THIS ASSEMBLY, AND YOU DO NOT WANT TO MAKE THE SAME MISTAKE THAT I JUST DID.

 

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This is the entire assembly. I think there's no way around motor work, without pulling the whole assembly.

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Riddle time: How many bolts can you remove from a vette headlight assembly, and not do anything?
Answer: Gimme' a minute; I'm countin' (where's my calculator).



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EDIT:
Disconnect headlight power supply.
Have ready a towel to put down the assembly.
First remove the screws at the lower assembly - with yellow circle.
Then remove nuts numbered '1' - at both sides of headlight assembly.
Then loosen, BUT DO NOT COMPLETELY REMOVE, the '2' numbered nuts.
Get your free hand onto the headlight assembly, and apply pressure. Then remove the two remaining nuts #2.
CAREFULLY, pull away the assembly.

Removal of the motor from the assembly is at post # 20, in red.

Motor disassembly is at post # 32. I have some pics between here #5 and #32 which might be of help.
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later...
The roll pin (previous post, blue circle) was tough. I was afraid of manglin' it. I put the penetratin' lube on it, then put the vise grips on it gently and squeezed, so the pin would close a little, and allow the oil to get on the outside of the pin. Turn slowly, and work it - it is tight!!!

I didn't pull it all the way out either - below, red circle. Also note the position of the shaft that it came out of, when disassembling the motor. Now go to post 32.



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Let it snow!

Hopefully, this powder is the problem.

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Is that a plastic gear? Did the powder come from the gear? What does the worm gear look like? Inquiry minds wanna to know.

 

Yup - it's plastic/nylon. And the previous owner, or somebody for him, has been in there before. The bolt that I showed with a yellow 'x' was gone.

All the parts are cleaned and drying. The plastic gear bein' shredded explains the skip, but not the exact pattern of skipping every single time. 3 seconds of skip after closing, 3 seconds of skip after opening. That's gotta be an electric problem???

When the parts are dry, they'll go back in lubed, till the new gear gets in. I'm probably gonna' go with another nylon gear.

If you do a complete disassemble, the only warning is to watch out for a single ball bearing, at the end of the worm drive.

There's another 5 ball bearing, with a separate race (washer-like cover), at the other end of the worm drive, inside the manual turn handle. The cover goes to the inside.

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Not necessarily an electrical problem. Even though the gear was stripped, it obviously had enough gear remaining to open and close the assembly,AND, to strain the motor enough after the assembly had bottomed out to trigger the sensor to shut off the motor. I would wait and see how it does after you get everything put back together before I made that call.

Side note...You said that only one side was acting up, kinda makes one wonder how longbefore the other side goes **** up.

 

Yeah good question. And good call on waitin' too...

Here's more pics from re-assembly:



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