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Re: Breaking gears in PG77
We used this gearbox on our intake in 2014 as well, and we experienced similar problems. If I recall correctly, we burned out a few motors and had issues with the "D" coupling on the transmission output shaft. We had to disassemble and reassemble it numerous times at our first district event, and we ultimately switched to pneumatics. We have avoided using it ever since (No offense Andymark).
If you are interested in changing to a different gearbox, I would suggest a VexPro VersaPlanetary Transmission. They are extremely versatile, and they can face mount using 2x 10-32 screws. We have been using them for the past two years, and we haven't experienced any problems with them thus far. This year we are using four of them on our robot, if that convinces you of the confidence that we have in them. If you are face mounting the PG71 right now, unfortunately the hole mounting patterns aren't the same (1.378" bolt circle diameter vs. 2.000"), but you might be able to mount the VexPro transmission using the four threaded holes on the side, or you might consider line drilling two new holes to accommodate it.
I hope you find a good fix, and good luck at District Champs!
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