** the second fill does not occur with any regularity. **
Than determining whether the valve is being power at the time may need to be done to try to isolate the cause further.
** I popped off the larger gear and put back on... Could that be the problem? **
The icemaker should only fill once per revolution. I can't see how putting the gear on the wrong way should change that but there might be a slim possibility.
** I was thinking of running a bead of caulk around the tray to allow for the added water **
That would be attacking the symptom (overfilling) but not the problem (the actual cause). That is not the way to go about servicing an appliance (or anything else for that matter).
IF it is overfilling, while such a fix might alleviate the symptom now, there's nothing to say the problem is going to stay exactly the same. If you do not find and correct the actual cause, it could get worse with time and you'll be back to square one. A further problem could even manifest itself at a time when you aren't around to catch it, making a real mess.
Fix it once and fix it right!
JMO
Dan O.
www.Appliance411.com
The Appliance Information Site
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