B6 A4/S4 Headlight Adjuster Gears

thingiverse

These are replacement gears for the headlight adjuster mechanism on my B6 A4 with bixenon headlights. The gears often break or strip leaving you with no way to adjust the aim of the headlights. The assembly shown is for the up and down adjustment of the headlight beam, I haven't had issues with the left to right adjustment. The gear profile was measured using calipers, so it's probably not an exact match to the original, but they appear to mesh nicely and work well. The gears aren't under high speeds or loads anyway. I would recommend printing the gears in at least PETG, PLA will likely deform and become useless under any moderate load. I printed mine in NylonX, which is similar to the material they're originally made in, PA66 GF30 according to the mold marks. The green gears in the images were just a quick prototype done in PLA.