I'm supprised that the handle (crank) didn't wear first. Did someone have vice-grips on it ? Try cleaning it up with a small file and then useing another handle, or switch handles on the drivers and passenger doors and see what happens.
If I had the regulator here I could repair it. The spline is just an old Chevy window and door handle spline. Maybe you can grind a flat on it and then epoxy a piece into the handle to take up the flat area. It's kinda Bubba but....... I would just fix it right and have it done with.
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