Walt,
Been there, checked everything, thought I was going nuts. Tried, as you did, another tuner and it worked great.
I have a ultrasonic bath cleaner that I use to bring old radio component metal parts to a good shine, IF cans etc. I put the tuner in the bath for several hours until it looked brand new, there were dirt deposits and fine metal deposits that came out of it.
The tuner worked great after that.
I hope this will give you some thought as to maybe a better cleaning process.
Best to you,
Mitch
Some variable cap designs depend on the metal-to-metal contact of the ball bearings with their inner and outer races to provide an electrical path between the cap's moving vanes and its frame. If the races get pitted due to corrosion or due to a broken ball, it causes intermittency and noisy operation when the cap setting is changed. This is difficult to fix short of replacing the entire capacitor. Lubing the bearings won't help much because ordinary grease is an insulator. There is a special electrical-conductive grease (impregnated with silver particles) made for this purpose, but if the races are damaged it will probably only be a temporary fix.