I went through the steps to install a new gear and screw. When I put the lift back together, it did the short travel thing. I read the solutions on this site and followed the instructions. I put the collar as far forward as it will go and reinstalled the cap and tested. Same thing. My opener is pre-1988 and the kit I received was a little different than the original. The kit had the collar being described here, but the original was held on with a brass busing. As I read the instructions, yup I read them, first time for everything, I installed the collar just as instructed and pictured. It looked just like the schematic. It is as far forward as it will go, I even stopped the thing in mid cycle to account for shaft travel caused by the screw pulling the shaft back as it turned. Now what? My pride is on the line now, I gotta get this thing to work.
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You said you adjusted the up limit already. Is it adjusted as far as possible? Usually the screw will become harder to turn. You mention a new door and spring but is the opener the same? My guess is you have a new opener as well and it is out of sync with the trolley. Try turning the up limit back and see if the trolley will stop shorter. If it does, loosen the chain or belt so that you can remove if from the opener's drive gear. Bring the trolley to your stop limit and put the chain/belt back on the gear. Adjust the chain/gear tension and try door operation again. If it was a sync problem, the door should close closer to your limit. Adjust up and down travel as necessary to fine tune it. This worked for me so good luck.
When it only travels a short distance, and back up and the light flashes, that means that it's encountered too much resistance and the safety mechanism puts it in reverse and makes it go back up. This prevents children or pets from being crushed. Make sure that the gears are aligned and the chain is not getting hung up. There has to be some resistance causing the safety mechanism to go off. Also, if there is a safety Infra Red sensor hooked up to the system, make sure that it's wired correctly and free of obstruction. This can cause similar problems.
You have to sync the limit switch with the trolly. Take the small white piece off the bottom of the gear and sprocket assembly. Rotate the center screw on the limit switch until it is all the way up. Put the chain back on the sprocket with the trolley in the up position. Put the small white piece on the bottom of the gear and sprocket assembly. Operate the opener with the trolley dissconnected from the door. You will have to adjust the limit screws on the side of the opener accordingly.
Ok well the best advise I can give you is to open up your opener case should be a 1/4 nut driver or a Philips head screw driver. Make sure to unplug it first. Once the case is off, find a reqtangle black box with three white plastic screws they are what controls the limits. Chances are they got knocked off wheny ou were putting in the gear. check to make sure the wires are hooked up and find the placement of the limits make sure they can touch each other. Little tip I do for my customs is get a piece of sand paper and rub it agaist the metal contacts for the limits only. (after time lift master openers bind up a film and dont stop where they supposed to.) If your still not sure how the limits work plus in the opener and run it make sure not to put your hands inside the opener and nothing esle is in the way. Then adjest the limits as needed. That should take care of you if not go ahead and make another post ill check back with you.
You say it only opens two feet?? Then closes?? If I may if you a little bit more costly option. Dont replace the gears. They used to be really good 8 years ago but the way they make the gears now there too soft and often strip out much faster. I would suggest that you do what we call a motor head change out. Take off your old chain drive motor head and buy a new one. Pretty simple. Two things though one always make sure you put the new one in with the door down. And the traveler in the down position ( The traveler is the metal thing hooked up to the chain) but far and your gear that you have it sounds to me that you dont have the gears close enough.. but 100 percent on that but a door should never close on it own. It's not safe.
Can you adjust the down-travel? On mine, it's a white nylon screw, on the left side, inside the light cover. Seems like there were instructions for this adjustment in the instructions for the gear replacement.
your door travel screw is set to go too far on the downward travel. you need to set the down travel. It is set to go too far down. find the screw adjustment on the unit that says close and back off the screw a full turn until door stops short of floor. then start turning screw other way until door just touvhes floor.