Hello James
Since you have said you have taken the car apart 3 x in one day then a few more times wont hurt . I say that because there maybe a few things going on at the same time . #1, when you have cracked wires always replace them . #2 , I would have it apart in my hand or on my bench and hook up the wires directly to the mechanism by it self , no other arms attached . If the plunger/coil work fine then go to step #3. #3 is where I check the two swing arms , the one where the milkman is attached and the one where the cans drop onto . Depending on its former life , one or both swing arms may be bent just enough to bind up . This is what was binding my milk car up . I slightly bent the arms up , slightly being the key word , or else the milkman's head will hit the upper door jam . I found this out the hard way . Note, make sure the milkman is pushed all the way down . I actually had to trim a 1/16 of an inch off the bottom of my guy for him to sit properly . You may also add a LITTLE oil/grease under the swing arms , there is a small tab that is on the arm that rides along the base of the car . One other thing to look at is the doors , do they swing open freely and spring back ? If one or both doors don't swing easy the plunger is not strong enough to force it open . I hope some of this advise helps in getting your car running right .
