Quote Originally Posted by Dave Owens View Post
When the deck lid stops check to see that the flipper is still firmly folded. Sometimes wear in the gear box allows the flipper to open slightly causing the flipper switch contacts to open thus stopping the decklid movement.
This was exactly the case. The gear box is a bit loose so the flipper doesn't fold deep enough every time to engage the limit switch and the cycle stops.

I guess there are no new gearboxes available so what would be the best solution for this problem?

Could the limit switch button be made a bit longer or have some extra padding on the flipper to the point which should hit the limit switch? It's not much what's missing, about 6 millimeters (0.24") that causes the problem.