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You should be able to see the teeth on the shaft, if you look at them from the side in good light. You probably can't see the teeth very well when it's installed on the car, which is why I suggested removing it. I can't imagine wear on the teeth of the gear, especially if the teeth on the other part look okay. But then, I haven't made a career out of examining window regulators, either. Have you replaced the pivot pin? You sure the noise doesn't originate there? From your description of the problem it's clear that there is a noise but I am not sure if you can see the window itself stop moving or drop slightly when the noise occurs. I suppose if it does it at the same point at every revolution of the crank handle, it has to be the small gear...
I was planning on selling the regulators in the future, I just hadn't gotten around to it yet. I'd prefer to sell the pair, as selling one would orphan the other one and the biggest market would seem to be with people doing what you are doing, going from electric to manual. Send me a PM if you want.
Thanks,
Jeff
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