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I have the same problem. I've probably pulled mine apart and unbound it 4 times since I first replaced the gear years ago when I got the car. I've shimmed one gear with a very thin washer, cleaned everything several times, tried to file off some of the extra bits left from moulding, applied grease, but I'm going to have to go through that procedure and try a few more things. Quite frustrating but at least I've done it so many times now that I can get it out, working, and reinstalled in about half an hour.
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