If you own a Lotus Esprit or Elan M100 manufactured between 1988 to 2004 then here is a kit to rebuild the headlamp lift motor.
The headlamp lift motor assembly comprises of a small high torque DC motor, gearbox plus external bell-crank lever.

Lotus Esprit and Elan M100 headlamp motor

Whilst the headlamp motor assembly appears to be reasonably robust, there is an inherent gearbox design problem.
It appears the three rollers inside the gearbox have been manufactured from a poor quality material.
Over time these rollers deteriorate when in contact with mineral grease and gradually break up into small fragments.
Typical symptom of headlamp motor/gearbox related problems are as follows -
1) Headlamp pod may be slow to operate
2) Headlamp pod may "flutter" and refuse to open fully
3) Headlamp pod may not open at all but the motor can still be heard running
It appears that both motor and gearbox assemblies are the same part but on closer inspection they are slightly different.
Checking the Lotus part numbers reveals the motor assembly plus relevant mounting bracket determines that they are handed.
B100B6064F (right-hand)
B100B6063F (left-hand)
The first step in removing the headlamp motor assembly is to disconnect the electrical plug.
Next step is to disconnect the motor lever from the push-rod.
The motor and mounting bracket are secured by three fasteners that need to be removed so the assembly can be extracted from the vehicle.
Once the motor assembly is on a work bench the the gearbox closing plate should be removed so the rollers can be inspected.
At the same time the motor should be dismantled so the armature and brushes can be inspected for wear.
In the event that the rollers have disintegrated then it is recommended the other motor and gearbox be examined because it will be of a similar age.
The gearbox should be thoroughly cleaned to remove all traces of grease and roller fragments prior to installing new rollers with silicon grease.

   Headlamp motor overhaul kit

The kit contains the following components-
a) Three Nylon rollers
b) One cork gasket for the gearbox
c) One cork gasket for the electric motor
d) Sachet of silicon grease

Lotus Marques supports local industry by manufacturing this overhaul kit in Australia.
Please note there are sufficient components to rebuild one motor assembly @ AU $20.00 plus GST

Please note carefully, pricing above does not included postage and packing.
All pricing information is in Australian Dollars and is correct as of 1/8/2020 but this may alter with time and currency exchange rate fluctuations.
To order your headlamp motor/gearbox overhaul kit, send us your parts order today

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