Finally...the trunk is sorted. I just wanted to post an update to help any others with future trunk woes. The main things I discovered are you need the right motor (Kimballs.com had four left when I ordered), the right tools (a gear puller to get the pinion off of the old motor - i got mine on ebay, but ended up getting 2 as the first was too small. You need the regular size, not the micro...). The next tricky bit was getting the pinion onto the new motor. A vice appeared to be the favoured way, but without one, I used a small clamp and the socket from a socket set. It worked a treat as it allowed equal pressure to be applied and the pinion could be pushed onto the motor shaft. Finally, align.trex have all the speciality greases a pinhead will ever need. I used SuperLube (
) Synthetic Grease and it sounds good.
With this done, the trunk span, finally at a decent pace and was working well. I then discovered a problem which took an age to find the solution for (but I did!). Every time the trunk was hit on the corner, there would be about half an inch give. This slack, or 'slop' in the gearbox could cause the ball to get stuck on the right side of the trunk. It was also annoying as I knew it shouldn't have any give.
Anyway, the solution involved removing the gearbox again (by this time, I didn't care...) and using a small/round screwdriver bit to tighten collar on the gearbox shaft. The round screwbit is pretty small and mine snapped off in the hole - but luckily it'd tightend first, so if you do ever have to do this, go careful!
Cheers, Andy