Also wanting to say thanks for this thread. In April 2010 I took my Jeep to the dealer for a strange issue pointing to this assembly as the problem. They replaced it, but Chrysler refused to cover any of the costs, so I ended up paying almost $3200 out of pocket to get the assembly replaced.
7K miles later, I'm experiencing a similar issue, pulled out the OPDA myself (thanks for the video - I wouldn't have felt comfortable any other way!), and found severe wear on the gear. I'm at a loss at this point, I don't feel comfortable making the shaft modifications (don't really have the money), and can't keep throwing money at this.