Lionel carousel 6-14109 binding

Ok I found that the horses upper ring was not moving with the floor so it was binding the horse ring assembly needed another 1/4 inch axial movement when assembling to get the gear that drives the horses in proper position.
however now the gear that is driven by the motor and floor does not engage the gear that drives the upper ring with the horses.
see pictures.  They are now axial aligned but radially they are off positions so no meshing takes place. The gear shafts are in proper position in their respective holes.  Everything seems lined up.
Any ideas?

Could you replace the gear in pic two with a larger diameter gear that will allow it to mesh cleanly with the other gear.

Replacement gears should be plentiful on the internet.

Thanks for the idea.
it seems that this unit was made in error without the correct alignment.  Closer inspection indicates that tooth engagement was so little to start it wore off the tips of the gears from use.

You might also try contacting one of our Forum Members who does 3d printing and see if a new gear can be printed in whatever larger size you would need, if you send him the original gear to compare.