I've resurrected this thread because I thought it had an interesting outcome.
In the end I decided that the best thing was to replace the pinion gear, but, knowing it would be long job I put it to one side and got on with other stuff. Two days ago my conscience started nagging and I decided to dismantle the drill.
The cover opposite to the handle came off OK, but it was obvious that the handle and cover also had to be removed. The wound spring caused problems because it was riveted to the pinion spindle. I tried, and failed, to extract the spindle, so I removed the spring from the spring-seat. I still couldn't see what was retaining the spindle so I tried gently tapping it out from the other end. That did it. The spindle and gear came out as in the photo. It was when I checked the gear carefully that the problem was revealed. The gear is secured to the spindle with a little roll-pin, which didn't fit properly and allowed the gear to rotate a little.
I measured the amount of rotation as shown in the photos (sorry about the nasty angle) which turned out to be 5.3 degrees. The gear has 18 teeth and an OD of 20mm, so the 5.3 degrees translates into 0.833mm of free play on the quill rack, which matches very well with my observations that started this thread.
I haven't fixed it yet – that's the next job, then I've got to get the spring re-attached to the spring seat.



