The roto unit was fully disassembled, cleaned thoroughly, lubed, and put back together.
1. Solenoid plunger stroke set to 7/8"... Check
2. Space between stop pawl and A-4185 is at 3/16" in rest position.. Check
3. In energized position drive pawl lift A-4184 has 1/32" of clearance from spinning ratchet and both pawls clear the ratchet... Check
4. Thin coating of white lithium grease on rivet disc... Check
5. Lube on gear teeth... Check
6. Lube shaft at bearing... Check
7. Leave some axial clearance when tightening spider... Check
8. Wiper fingers and springs move freely... Check
I've read some have had problems because the teeth are worn down or broken. Mine are in really good shape.
I've also read the pawls can get a groove worn into them that can cause issues. These are also in really good shape.
I still have the issue described in the first post. Anyone else have any helpful advice?