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Did I inadvertently change a setting when I took the unit apart to replace the gear on the motor?

Model # 139.53618SR Part # 41C4220A Replaced gear & sprocket on Craftsmen garage door opener. After reassemble, motor run 3 sec then reverses. Did I inadvertently change a setting when I took the unit apart to replace the gear on the motor?

It sounds like the limit switch assembly is out of time with the door lift trolley assembly. That can happen when replacing the worm gear if, for example, you removed the components when the trolley was in the door-down position but re-installed them when the trolley was in the door-up position.

Even though the spacing between the limits is still approximately correct, the overall start point for the movement no longer allows the mechanism to move far enough. That creates binding before the limit setting can be reached and can strip the worm gear or other sprockets as you mentioned.

To fix it you will need to remove the limit switch and then re-time it to the proper trolley position. If you move the trolley without the limit switch on the door could jam so remove the lockpin/clasp from the input gear on the limit switch and you can spin it to move the indicated door position on the switch without disturbing the prior limit spacing. You want to match the two so that, for example, the up-limit shows on the limit switch when the trolley is actually close to the up-position. Once the start point is close enough the door to work normally but you may still need to fine-tune the exact upper and lower positions according to the procedure in your manual or the door could over-extend and jam or reverse due to exceeding a load limit.

Another possibility is that the RPM sensor assembly was not reinstalled properly. There are a couple of things that can commonly happen there.

The Interrupter Cap/Cup is not on far enough. There is no specified position, but the cap needs to be on far enough for the notched ends to pass by the sensor so that the sensor is blocked, then open, blocked, then open, and so on. Normally that just means pushing the cap on until it stops sliding. The sensor needs to see that change or it assumes the door cannot move for some reason and reverses the motor to prevent any potential damage or safety issues.

The wiring to the sensor is connected incorrectly. The plug is not notched or asymmetric so it can be pushed on incorrectly with one or more of the prongs not actually in the plug. Again, the sensor cannot respond correctly and the motor is reversed to prevent damage or safety issues.