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I think your gear/tooth count theory is correct. For giggles, I found the window rolls too far up by about 2 inches past where it should. What if I cut the regulator arms then lengthened them by say, and inch or 1.5 inches? Would that in theory give more down stroke? Wait...I think shortening...

Well I tore into things this morning. There are absolutely no hang ups anywhere, the tracks despite no more felt material slide freely. The issue is pictured, the rollers literally run out of track. They hit the threaded lugs on the removable track pieces that bolt to the window. These are...

I've had it torn apart before. Felts are all gone. But the tailgate itself is off a Civi K5 and is very solid and straight, I welded the top edges about 4 years ago. It works smoothly. The regulator is my suspect right now. But it looks just like the photos on the net, and its supposed to be...

I have no other trucks to compare to. My M1009 rear glass sticks up about 2 or 3 inches when fully down. That doesn't seem right, as it's too easily susceptible to damage when loading, sitting on the tailgate, etc. So something aint right with mine. I deem the regulator non original to the...