Mid-repair" is the worst part of that story. That's like the universe picking the worst possible time to mess with you. Total nightmare scenario right there.

Check if the new gear is nylon, that's what they use to fail on purpose and save the motor. My Genie ate three of them before I gave up and just got a whole new rail assembly.

Ever get that feeling you're fighting the house itself? I had one last month where the wind was just wrong for the whole street layout. Checked everything inside twice before it hit me.