Well Mad max if I had read that first before I went back at it, it would have saved me a lot of time. In my own roundabout plodding way, that is the conclusion I came to as well. I disengaged the motor, turned the gear a little, Re-engaged the motor and hey presto. Working like a dream. You are spot on. It was in a garage getting heater plug replaced, and I thought someone had been rooting around in it. I guess they must have stood on the step before it was fully opened and damaged the gear. I may put up a big sign as herself has nearly done it a few times as well. It is a weakness in them imo.
Anyway, well spotted and thanks to you and everyone who gave advice.
This is a great forum, and I for one would like to thank Ally for all his work.
Maybe a way to donate a few bob if you are helped out might be an idea to keep it up and running
Thanks everyone