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So this issue has been resolved. It turns out that there is a connection to the brake on the rear flap motor right where the wires enter the motor case. the wires themselves (Red, Black and White for the brake) are wrapped in a braided shield that is tied to ground. It looks like there was originally some sort of insulation applied to the connection, but this wore off over time, allowing the shield to occasionally contact the exposed terminal and actuating the brake. We found this when after reassembly the mechanism was still intermittent. We pulled the motor out and while we had it connected but not tied to the mechanism we wiggled the lead entering the motor and it made the motor start and stop. Inspection found the exposed terminal issue. We applied some high temp silicone to the exposed connection and put everything back together and it works properly. So if you see this problem, try wiggling the leads where they enter the motor case and see if this causes it to be intermittent. This lead is typically tied to the motor case with a zip tie or clamp for strain relief, so it normally doesn't move much but apparently enough to create the problem.
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