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Our drivers side head light door does not come up all of the time. Sometimes prior to starting the engine I will try the manual light switch on the turn indicator lever and both doors will open, but not all of the time. When only the passenger door opens, I will manually open the drivers side door by removing the rubber cap and turning the **** on the actuator.
Lately after I have opened the door manually, their is a 'cluttering' noise from the actuator that I manually opened after the door has closed. To further check this out, with both doors opened, I removed both rubber caps, turned the engine off, after the delay both doors closed and the ***** on both actuators rotated until the doors were fully closed. The actuator on the passenger side stopped rotating, the actuator on the drivers side continued to rotate for 3 seconds with the 'cluttering' noise. This can not be good and I fear something is going to fail soon.
Sounds like the plastic gears are giving you a problem. I thought I had a good link on that but cannot find it now. I will look a little later when I get a chance.