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I'll answer in order:
First, I would agree with Chris that you should be using 6 screws instead of 3, longer ones. Your set up sounds pretty solid as a whole, but the failure could be the result of uneven loading from things not being tight enough. So, make sure they are tight enough (not too tight) and consider using Loc-Tite.
You should very strongly consider using fans on the motors, the absolutely will overheat, and eventually fail, without them. We use two fans per motor. Always. Also, tie wraps should be fine for keeping the shifter in place, these gear boxes are pretty good at staying in gear.
Finally, you probably should just check the connections on both the OI and the robot controller. It's possible that you are having some sort of freak overloading problem, but more than likely you have a bad connection somewhere, and that is why you are getting the "no data radio" light.
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