New gear or servo need for Guest 22040 spotlight

My Guest 22040 spotlight has a stripped brass gear for the up/down servo. Anyone know where I can get either the gear or the entire servo/gear assembly? Not much interested in a $380 new light as the solution. Thanks! Gear is on the left, and as you can see its tiny.

Combo update and bump: We found the problem isn't with the teeth but with the attachment to the servo shaft. The servo is just spinning and not turning the gear. Looks like there is a tab stripped off of the inside of the gear which would lock it to the shaft. Worst case we are just going to try to bond the gear to the shaft if we can't find any replacements. Do you think coating the shaft with 5200 and slipping the gear over it would end up with a bond that wouldn't slip when in use? I haven't used it but all the posts on here say 5200 is a strong permanent bond.

OK, I am making progress. I know the thousands of you following this thread are on the edge of your seat. I contacted Marinco, the manufacturer and they sent me a nice list of the major parts with pictures and part numbers. Turns out I have to buy the entire motor with the gear already attached. Part number is 22029. Below is picture:

My last post on this: I talked to Marinco and the parts for the Guest 22040A spotlight can be ordered through an authorized dealer. West Marine is one so I ordered the boot and the motor I need from them today. Looks like it will be about $90 total for the two items. Better than a $350 new light. For anyone else who might need to do this, here are the replaceable parts and their part numbers:

Boot:


Horizontal Gear (part # 22091):


Vertical gear (Part # 22090):


And the motor is shown in the previous post.

Well, I completed this repair. I replaced the vertical motor (with the gear attached) and the weather boot. If anyone decides to take on these kind of repairs here are some pointers:

- Remove the light from the boat and take it home. Its a tedious job working with small parts. You'll want to take breaks and regroup at times.
- There are two set screws at the upper neck of the pedestal. Remove those first and the cable clamp at the bottom of the pedestal. Then slide the pedestal down out of the way.
- I completely removed the cable once I pull the servo out of the housing to make it easier to work on. To do that you have to use a soldering iron to remove the four wires from the two motors then pull the cable through the hollow post.
- In replacing the vertical motor, the vertical gear was in the way so I had to first remove it. You will need retaining ring pliers to get the gear's retaining ring off and to put it back on. Its too stiff to spread open with a screwdriver.
- Putting a new boot on was a real pain. First clamp down the boot in the rear. Then bend the boot down through the bottom slot to be able to get the post of the servo through the hole in the boot. Then push the boot back up and clamp down the front of the boot. Now you'll still have four mounting screw to put through the boot into the servo legs. The little holes in the boot won't be easy to line up. Make those holes much bigger (or convert them to slots) so the boot doesn't block your view in getting the mounting screws into the legs of the servos. Also, its too hard to hold the little nut and metal piece that clamps the boot in the front and back. Just tape the nut to the metal piece right over the hole so that you don't have to line up the nut with the hole while you are putting the screw through.

Great post. To bad no one commented on it. My light goes up and down and from Right to Left but will not go from Left to Right. This post may come in handy. Thanks!

Thanks for posting - I know a friend with a 2006 - 340 had the same problem. Glad you shared - great post.

Thanks for posting - very helpful. Trying to determine the difference between the 22040 and the newer 22040A, I wonder if they improved that part that failed on yours perhaps? I'm looking at a NOS 22040 online but maybe it's not worth the trouble....

I have the Jabsco version and the guts pretty much fell out of it. I riggeed up an aluminum brace and now it just points forward. Good job fixing yours.

Old post @ZZ13 but thank you! My light goes up and down but not side to side. Going to get it off the boat and see what needs replacing.

Great thread. Many thanks for the info. My light has the broken vertical motor gear as well. I call Marinco today and it turns out that motor is discontinued with no replacement.

So I'm looking into re-gluing the gear on to the shaft. Any suggestions are welcome. I'm thinking jbweld and some big magnifying glasses. Other suggestions would be very welcome.

Also has anyone had good success finding reasonably priced replacement bulbs. The best I've seen is some $93 bulbs on-line. Someone mentioned going to an auto parts store.

Google the part number.

Ebay often sells NOS (New Old Stock) items.

Tom MK said:

Great thread. Many thanks for the info. My light has the broken vertical motor gear as well. I call Marinco today and it turns out that motor is discontinued with no replacement.

So I'm looking into re-gluing the gear on to the shaft. Any suggestions are welcome. I'm thinking jbweld and some big magnifying glasses. Other suggestions would be very welcome.

Also has anyone had good success finding reasonably priced replacement bulbs. The best I've seen is some $93 bulbs on-line. Someone mentioned going to an auto parts store.

Click to expand...

The original is a PAR36 aircraft landing light. They only have a 50 hour rated life and as they get older they get dimmer, the tungsten clouds the lens. Not all that good when new.

I went with LED for John Deere tractor RE2516 high/low much better
I had to enlarge the alignment notch slightly and a little tight getting the band on but with a little patience it fits.

https://www.ebay.com/itm/RE25126-RE...693099?hash=item2a755d92ab:g:e9gAAOSwpONZQ-yb

Pat - Thanks I'll check out the RE2516. -- also ur video is great. watched it several times a while a go. Definitely appreciate the numbered tags.

CaptRonn -- Unfortunately Ebay and many other vendors seem all out of stock. Fortunately the vendo did have the rubber boots.

I'm going to try JBWeld and trying to rough up the surface a bit. If that works reliably I'll go looking for the LED bulb.

Tom MK

Great post! Thank you!

Tom MK said:

Great thread. Many thanks for the info. My light has the broken vertical motor gear as well. I call Marinco today and it turns out that motor is discontinued with no replacement.

So I'm looking into re-gluing the gear on to the shaft. Any suggestions are welcome. I'm thinking jbweld and some big magnifying glasses. Other suggestions would be very welcome.

Also has anyone had good success finding reasonably priced replacement bulbs. The best I've seen is some $93 bulbs on-line. Someone mentioned going to an auto parts store.

Click to expand...

If you're still looking this bulb fits perfectly and works as expected. $15 on Amazon AmazonSmile: Wagner Lighting 4700 Sealed Beam - Box of 1: Automotive

I got the bulb and vertical axis working fine but as I took it apart to install the boot now my horizontal axis seems to be sticking in a few spots. I don't see any obvious signs of broken teeth or such.

Has anyone opened up and replaced the horizontal gear? If so how did you disassemble the mount?

I've been able to disassemble the light to get at the vertical gear but the horizontal gear and motor seem blocked in by a box that is tack welded closed. I'll try and follow up with photos later.