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Originally Posted by Teamcodeorange
We had this same problem. The only solution we found was to put super glue all the way around on the part of the large gear that fits into the gearbox. Make sure the super glue only goes on the right part before you insert it, so you don't glue other things together. It isn't the most elegant solution, but it worked.
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Any chance you could post a photo?
Seizing gears, in any gearbox, are typically a sign of misaligned shafts. Misaligned shafts come from a couple of different places, including housing plates that aren't perfectly parallel. In 2008, we replaced our SuperShifter housing with plastic spacers -- since the plastic deformed under stress, the plates became non-parallel and the entire gearbox was incredibly inefficient.
Did you guys make sure that all of the gears seemed to free-spin properly prior to attaching the motors?