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You're going to have to take things apart anyway, so report back after you've tried:
1. Fully charge all batteries. What are their voltages according to your multimeter?
2. Degrease everything in the mechbox. Remove the entire cylinder assembly, anti reversal latch, and the cut off lever, thus keeping only the gears. Screw the two halves together. Don't forget the motor cage screws - tight but don't over tighten because you will strip something without the cage in place.
3. Test shimming by spinning the gears. You should be able to get 2 or 3 full revolutions of the sector gear. Remove shims if its too tight. The interface between the 3 gears should be good, but don't try to achieve so much contact that the flat surfaces of the gears touch each other.
4. Reinstall only the cylinder and piston assembly - don't put the spring and spring guide in. Try to use gravity to simulate a pullback of the piston. Is anything binding?
5. Examine the motor brushes. If the motor is old and brushes are worn more than halfway, you will need to change them.
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