Our Banebots started doing the same thing so as soon as Fisher Price gearboxes got in stock in AndyMark, we jumped on the opportunity:
Basically we got this:
http://www.andymark.com/ProductDetai...ctCode=am-0822 (the motor) and used their planetary GEM gearboxes and stacked multiple ones to get the ratio we want:
First stage:
http://www.andymark.com/ProductDetai...ctCode=am-0449
Additional Stages:
http://www.andymark.com/ProductDetai...ctCode=am-0301
After we put this beefy thing in, we don't expect to have any more gearbox problems. Be forewarned, the whole assembly for a 180:1 ratio for us weighed about 7 pounds...