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Re: Major mechanical problems....
Motors draw a lot of current because they are put under a high load. By pushing the motor's beyond 40 amps just by putting more stress on the motors, it would appear that there is too much load in your drive system. You may have some parts which are not able to move as freely as they would like to. You also may have problems with parts of your drive train being misaligned. Any of these issues can cause the motors to draw too much current.
As for my suggestion in solving the problem: put the robot up on blocks and run the drive train. Stress it. Watch how the drive train reacts. See if anything doesn't align. See if anything hits anything else. That will help you diagnose the problem.
Matt
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