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Originally Posted by davidthefat
mentioned that the hex shaft needed more spacing from the body.
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I think you are missing (or have put in the wrong place) a spacer of some sort. The hex shaft should not wear like that. I don't think it should even be touching a surface that it will move relative to (i.e., anything other than the gear, the race of a bearing, or a spacer that rotates with the shaft).
Unfortunately I can't confirm this as I can't look at the CAD file, and the pdf of the layout does not show the gears or spacers.
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Other issue might have been a bearing that was not properly fastened that might caused the shaft to jiggle.
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Any tiny misalignment in the shaft will increase the rate that it wears, and if the misalignment is large enough, it might stop the gearbox entirely. All parts should be secure, if something is capable of moving in any direction other than what is intended (anything other than rotation with the shaft), chances are something is wrong.