If you or someone else will send me the gear I can draw it and share the file with everyone. I can 3D print it also, but I wouldn't be confident that it would last in any plastic/nylon, etc. that most printers print with. IMO a better solution is to get it CNCed from aluminum, the only problem then is whatever will end up taking over the top spot as the weakest link in the assembly.
If someone does send me one, when disassembling please see if the recess can be left off so that that area becomes a flat surface. It'll be much less expensive to CNC without it.

 

It looks like that gear had 2 broken teeth. One on each end of it. I just found the other piece wedged under another piece. It looks like that gear must be pressed on. Also that red area that was drawn in doesn’t matter if it is solid. After looking closely at it when you push in on the lever, it does not look like it has anything to do with damaging the gears like I thought.
I also noticed that if you wanted to buy a door handle that was the wrong color like off of eBay or something, changing just the lever is pretty easy since it is the only thing painted. . You could swap your existing one. Just remove this gasket and that lets a pivot pin slide out then just remove the 2 wires that are connected to it.

This lever is connected to the broken gear on the other side. This is what kicks the handle in and out.

Shows handle and gasket removed and pin sled out.

 

You also have experienced the backup camera fogging? I had my camera replaced and then the new second camera fogged up. I used to not drive my LC much. Since then, I have now been driving it daily, it no longer fogs up. If you look at the trunk bolts, you can see corrosion there too. I have never driven my car in the rain and its garaged. Only Touchless carwashes is what I can think of. Where do you think the intrusion into the camera is happening? I was thinking there is a second outer lens covering he camera and that is where the water is getting trapped? Someone posted that after they wash their car, they leave the trunk lid open.




https://www.clublexus.com/forums/lc-...parked-lc.html

 

This helps! Looks like corrosion is affecting the motor and the plastic gearing is degrading. Lexus should recall this and improve the water protection and replace the plastic gears with a better plastic. Report this to the National Highway Traffic Safety Administration to get this to become a Recall Campaign.

https://www.nhtsa.gov/report-a-safety-problem

 

@Johnnyman1 , is this where it broke?



Are there other gears? The zipping noise people hear are gears stripping.

 

There is another gear that is two gears in one and fits between these 2 gears you see here.
on mine that black half gear broke one tooth at each end on both sides. You can see gaps at both ends. Should not be any gaps at all.

Here are where both teeth broke
One other thing is my car is a 2018 and the drivers door has been replaced 3 times already. I now have it were it only unlocks the drivers door so I can save wear and tear on passenger door handle.

 

Mine is a 2018 too. How do you set it to only open driver side? Seeing that the gears are breaking at the end points, it may mean the motor is still running and putting too much torque at the end points resulting in the stuttering noise and breakage of gears.

For example, I have a machine at work that uses a worm gear lift motor to raise and lower a section. There is a blue sensor device that counts the revolutions of the gear and slows the motor and then turns off power to the lift motor when it reaches max and lowest heights. That little counter device was failing over time and prematurely cutting power off and I had to replace it.

I wonder if the motor in the Lexus actuator has something similar built into the motor or a sensor that determines electrical power draw that tells the motor to stop when the handle is fully extended and retracted that fails because of corrosion and so the motor has no idea when to stop and that is why you hear the clicking because the motor is still running.

 

Vehicle customization has the door lock settings.
Does locking and unlocking the door affect the gears that extend and retract the handle?

 

I see a future after market opportunity for some reproduction aluminum gears.. Not sure what would take care of the erosion issue though.

 

Possible Theory- Today, I went on a Late Summer Country Drive in the Bay Area. It was Dry And Warm and no humidity. When I arrived home and was backing my car, I noticed condensation in my backup camera. The only water and moisture was from the windshield wiper cleaner that I used a couple of times because of bug splats. You can see that watermarks that the wiper spray streams over the roof and sides of the car and into the trunk space. I pulled the trunk liner and you can see corrosion on the trunk lid bolts. I think when they replaced my camera, they didn’t clip the white clip correctly as it looks off. Anyhow, the condensation in the lens went away after some minutes after I parked and it was sitting in the sun.

 

The motor actuator for the door lock assembly can be purchased separately from Lexus instead of having to buy the entire assembly for $1300. Lexus 69030-11010, 69040-11010 Front Door Lock Assembly W/Motor, either right or left $280.

 

I also have the 2018 had it done at the dealer. Was covered under the extended warranty. 37K miles always stored in winter Nov-Apr. Out of the elements, I believe its a constant with not the right materials used.

 

I may be wrong but looking at that part# and description. It looks like that might be the locking part because it says it comes with the latch. Picture also looks like that part. I wish there was a cheaper way to repair our outside door handles but I do not think this is it.

This is what I found.

 

Ugghhhh. Just got home from a quick shopping trip, hit the lock button on my remote and heard a horrendous grinding sound. Now the driver side door handle will not open automatically. Grinding noise every time I hit the unlock or lock button. I can open it manually thankfully. What a pain in the ***.

 

Are you still under warranty with your 22'?