Thanks so much @trash treasure and @Scoutmom103 I’ll work today to de grease those gears and free them. Probably a good thing to do anyway.
Ive read the service manual for the 591, the 191s contemporary counterpart carefully and I am positive the hook itself is not timed correctly according to the timing requirements of the machine.
@jimi Unfortunately adjusting the needle bar alone is not enough to remedy the situation. The hook and needle bar each have timing requirements they have to meet. Changing the needle bar to meet the hooks out of time position is not fixing this timing issue. The needle bar needs to be at a specific place in its path (2mm from bdc in this case) to have time to form a loop that the hook can catch properly. I can change the height of the needle bar to meet the hook, however, the hook then meets the needle a hair after bdc (bottom dead center) which does not give it time to form a loop. The hook then barely catches the loop sometimes, slices and splits the thread sometimes because the loop is tiny and too tight to catch, or misses it altogether sometimes.