Not sure but the point is just so that you don't replace it with the worn portion being in the same place as before. I don't think it has to be exact just that its basically at the opposite end as before.

Ok so I just want to rotate the worn part from its current position by 180 degrees. Should be simple enough but I'm still unsure of how to do this without taking off the metal cover like in the video

Thanks all. Yes, you are rotating the gear 180. Without the line, you won't know if you did so. The people that have done this, some say this fails on them right away. I have a feeling it is because they did not flip 180. You need to mark the white gear before you take the motor out.

If you take the motor out, the gear will rotate. You won't be spinning it 180 anymore. Get it. You need to mark the gear, white visible part on the outside.

It is very hard to see inside the motor shaft hole, and then judge the 180.

Just unbolt that thing, it will take you 3 min. You will see the white gear.

Ok follow this exactly.

1. Unbolt actuator from X case.
2. Take off the little ground wire, and the main harness.
3. The actuator is in your hand with the motor still attached.
4. Mark said white gear on the outside, extend the line to the metal plate
5. Mark one side of your gear with a plus, that way you will know you didn't put it back in the original position.
6. Take out the 4 screws that hold motor to the actuator.
7. Remove motor just like in the vid. Hold onto that harness connection, or you will be putting the brushes back in one at a time. It's not the end of the world, I took my motor apart just to see.
8. Once the motor is out, the white gear spins freely. You can now spin it till you are blue in the face.
9. Line up the marks, and assemble.

You are done.

I'm going to try this and hope for the best. I guess the worst thing is I have to pull it off again.

Anyone know the bolt and screw sizes so I can't make sure I have them?

Click on the link that TwinsPoppa provided for you earlier. I did a write up a while ago.

Will I loose any fluids when I take this off the transfer case?

No you will not. It is not connected like that. It is an external device.

Ah. Thus why my premium warranty didn't cover it :/

Has anyone tested the part from this vendor?
My gear wasn't worn out as badly. My problem was actually fixed by replacing alternator regulator. I suspect this gear issue was originally caused by voltage surge.

However, it still makes grinding noise occasionally without lightening up the dashboard. Very annoying.
If any one has used the gear from this vendor successfully please let me know.

The Italians are selling this for $300 plus on ebay. Thanks in advanced.