I had the same problem whereby you could hear the gears clicking. First remove the orange gear. Further searching found how to reset the micro to default. While pushing both the prewash and soak together rotate clockwise the rotary knob to pump out and wait for all the lights to illuminate then rotate the rotary knob anticlockwise back to stop. The dispenser motor will then rest to the home. When finished replace the orange gear. It can only go on one way with the teeth facing the other gears. I also noticed the second tooth in on either end of the orange gear was missing. I couldn't find any broken teeth so I assume this is standard. Is your's the same.
John Korvemaa, January 2007