Tom, IIRC you can rotate the gear to a new position so that it doesn't use any teeth that are missing. I think the gear travel is less than half, maybe a third?
When I purchased the upgrade kit, it included a new switch and a note that the step would operate incorrectly with the old switch. The old switch is a mechanical push switch while the new switch is magnetic. However, I found that on my coach. The step did operate correctly with the existing switch, for which I was grateful (one less thing to have to modify).
i took the gear box out and took it apart. as you can see, the aluminum teeth in the gearbox are bad. i think the motor is fine.
fortunately i have a few of these laying around so i built one good one out of a bad gearbox and one with a bad motor.
now i have to get a different plunger for the door switch
looks like newell used one of their own. i will have to look.
tom
the kwikee plunger switch is like 20 bucks. it is actually a cole hersee switch which i ordered from napa for 5 bucks.
tom