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Jeff
You are right the visible gears on the arm are not in bad shape so one would assume the window crank gears are also OK
The only external difference between the Drivers side and the Passenger side manual regulator is that the passenger side pivot pin was half broken off, but it still kept the spring in tension. Could a little loss in tension in the spring cause the problem?
To replace the pivot pin that I assume I grind off the peened over end of the pin? The replacement pin I see has a hole for a screw to hold it in.
Thanks for you time
dog
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