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What gears are we talking about not meshing correctly? The teeth between the regulator arms?
That be the ones!!
Yup. That's them.

decided to clean up the house and get rid of old magazines
John- Check to see if your lift mechanism is bound and will not let the motor/gearbox drive it far enough to lift the window all the way up. The motor will turn the gearbox until something stops it- like the window going all the way up or being all the way down. No limit switches in there to electrically de-energize the motor- that's one reason the plastic gears split. I would check to see that the mechanism itself is not binding somewhere somehow that it won't lift the window all the way.
One note- if the two quadrant gears become unmeshed (dangerous situation really as the spring that helps lift the window is a strong SOB) you must be certain that they are re-meshed in the proper position with one another. I've been down this road before.
Good luck I am interested to hear what you finally determine to be the culprit. Gary S (Shmukster)
Pighead, what I am confused with is that I was able to swing the arms together through their full range of motion before I put the regulator in the tailgate. So I'm confused how it could decide to bind up when it was smooth before![]()